Methods, systems, and devices for controlling electrosurgical tools

ABSTRACT

Various exemplary methods, systems, and devices for controlling electrosurgical tools are provided. In exemplary embodiments of methods, systems, and devices provided herein, a control system can be configured to monitor an electrical parameter during end effector closure, e.g., as jaws of an end effector of an electrosurgical tool move from an open position to a closed position. In response to the electrical parameter dropping to a predetermined minimum parameter threshold, the control system can be configured to cause the end effector to open.

FIELD

The present disclosure relates generally to methods, systems, anddevices for controlling electrosurgical tools.

BACKGROUND

More and more surgical procedures are being performed usingelectrically-powered surgical devices that are either hand-held or thatare coupled to a surgical robotic system. Such devices generally includeone or more motors for driving various functions on the device, such asshaft rotation, articulation of an end effector, scissor or jaw openingand closing, firing or clips, staples, cutting elements, and/or energy,etc.

A common concern with electrically-powered surgical devices is the lackof control and tactile feedback that is inherent to a manually-operateddevice. Surgeons and other users accustomed to manually-operated devicesoften find that electrically-powered devices reduce their situationalawareness because of the lack of feedback from the device. For example,electrically-powered devices do not provide users with any feedbackregarding the progress of a cutting and/or sealing operation (e.g., anactuation button or switch is typically binary and provides no feedbackon how much tissue has been cut, etc.) or the forces being encountered(e.g., toughness of the tissue). This lack of feedback can produceundesirable conditions. For example, if a motor's power is not adequateto perform the function being actuated, the motor can stall out. Withoutany feedback to a user, the user may maintain power during a stall,potentially resulting in damage to the device and/or the patient.Furthermore, even if the stall is discovered, users often cannot correctthe stall by reversing the motor because a greater amount of force isavailable to actuate than may be available to reverse it (e.g., due toinertia when advancing). As a result, time-intensive extra operationscan be required to disengage the device from the tissue.

In addition, electrically-powered devices can be less precise inoperation than manually-operated devices. For example, users ofmanually-operated devices are able to instantly stop the progress of amechanism by simply releasing the actuation mechanism. With anelectrically-powered device, however, releasing an actuation button orswitch may not result in instantaneous halting of a mechanism, as theelectric motor may continue to drive the mechanism until the kineticenergy of its moving components is dissipated. As a result, a mechanismmay continue to advance for some amount of time even after a userreleases an actuation button.

Accordingly, there remains a need for improved devices and methods thataddress current issues with electrically-powered surgical devices.

SUMMARY

In general, methods, systems, and devices for controllingelectrosurgical tools are provided.

In one aspect, a surgical system is provided that in one embodimentincludes an electrosurgical tool including an elongate shaft, an endeffector at a distal end of the elongate shaft, a cutting elementconfigured to translate along the end effector to cut tissue grasped bythe end effector, and a housing at a proximal end of the elongate shaft.The surgical system also includes a sensor configured to sense animpedance of the tissue grasped by the end effector, and a motorconfigured to drive the translation of the cutting element along the endeffector at a speed based on the sensed impedance and based on a currentof the motor during the translation of the cutting element along the endeffector.

The surgical system can vary in any number of ways. For example, thespeed of the translation can be reduced in response to the sensedimpedance being below a predetermined threshold impedance and thecurrent of the motor being below a predetermined threshold current. Thespeed of the translation can be increased in response to the sensedimpedance being above the predetermined threshold impedance and thecurrent of the motor being above a second predetermined thresholdcurrent that is lower than the first predetermined threshold current. Inat least some embodiments, the speed of the translation can be reducedin response to the current of the motor reaching the predeterminedthreshold current, and the speed of the translation can be increased inresponse to the current of the motor reaching the second predeterminedthreshold current.

For another example, the speed can also be based on a distance of thecutting element from a start position of the cutting element before thecutting element begins to translate. For yet another example, the speedof the translation can be reduced in response to the current of themotor reaching a first predetermined threshold current, and the speed ofthe translation can be increased in response to the current of the motorreaching a second predetermined threshold current that is lower than thefirst predetermined threshold current. For still another example, thesurgical system can include a tool driver configured to be operativelyconnected to the housing, and the tool driver can include the motor.

For yet another example, the surgical system can include a controlsystem configured to configured to actuate the motor to drive thetranslation of the cutting element. The control system can be configuredto control the motor to constrain the current of the motor between afirst predetermined non-zero threshold current and a secondpredetermined non-zero threshold current that is lower than the firstpredetermined non-zero threshold current. The control system can includea processor. In at least some embodiments, a surgical robotic system caninclude the control system, and the surgical robotic system can includesa tool driver that includes the motor and that is configured tooperatively connect to the housing.

For another example, the electrosurgical tool can include at least twoelectrodes configured to apply energy to the tissue grasped by the endeffector. For yet another example, the cutting element can be a blade onan I-beam configured to translate along the end effector. For stillanother example, the end effector can include a pair of jaws that graspthe tissue therebetween.

In another embodiment, a surgical system includes an electrosurgicaltool including an elongate shaft, an end effector at a distal end of theelongate shaft, a cutting element configured to translate along the endeffector to cut tissue grasped by the end effector, and a housing at aproximal end of the elongate shaft. The surgical system also includes amotor configured to drive the translation of the cutting element alongthe end effector at a speed, and a control system configured to controlthe motor to drive the translation based on a distance of the cuttingelement from a start position of the cutting element before the cuttingelement begins to translate and based on a current of the motor duringthe translation of the cutting element along the end effector.

The surgical system can have any number of variations. For example, thecontrol system can be configured to control the motor to prevent thetranslation until the distance of the cutting element from the startposition increases to a predetermined threshold distance, and thecontrol system can be configured to control the motor to constrain thecurrent of the motor between a first non-zero threshold current and asecond non-zero threshold current that is lower than the firstpredetermined threshold current. For another example, the surgicalsystem can include a sensor configured to sense an impedance of thetissue grasped by the end effector, and the control system can beconfigured to control the motor to drive the translation also based onthe sensed impedance. For yet another example, the surgical system caninclude a tool driver configured to be operatively connected to thehousing, the tool driver can include the motor, and the tool driver andthe control system can be components of a robotic surgical system. Foranother example, the electrosurgical tool can include at least twoelectrodes configured to apply energy to the tissue grasped by the endeffector. For still another example, the control system can include aprocessor. For yet another example, the end effector can include a pairof jaws that grasp the tissue therebetween.

In another embodiment, a surgical system includes a treatment tool shaftassembly having a pair of jaws at a distal end thereof and having aclamping assembly configured to move the pair of jaws from an openposition to a closed position. The clamping assembly includes an I-beamthat includes a tissue-cutting blade. The surgical system also includesa drive assembly operably coupled to the clamping assembly andconfigured to drive the clamping assembly to move the pair of jaws froman open position to a closed position and to drive the blade throughtissue, a motor operably coupled to the drive assembly, and a controlsystem configured to monitor a load on the motor as the blade passesthrough tissue and to decrease a speed of the blade when the motor loadreaches a predetermined upper motor load threshold and to increase thespeed of the blade when the motor load reaches a predetermined lowermotor load threshold.

The surgical system can vary in any number of ways. For example, thepredetermined upper motor load threshold can correspond to a firstcurrent of the motor and the predetermined lower motor load thresholdcan correspond to a second current of the motor that is less than thatfirst current of the motor such that the control system is configured todecrease the speed of the blade when the current of the motor reachesthe first current and to increase the speed of the blade when thecurrent of the motor reaches the second current. For another example,the control system can also be configured to control the blade based onat least one of an impedance of the tissue and a longitudinal distancethat the blade has moved from an initial position thereof. For yetanother example, the control system can include a processor. For stillanother example, each of the pair of jaws can include at least oneelectrode thereon that is configured to apply energy to tissue.

In another embodiment, a surgical system includes a surgical toolincluding an elongate shaft, first and second jaws at a distal end ofthe elongate shaft, a housing at a proximal end of the elongate shaft, aclosure assembly disposed at least partially in the housing andconfigured to be actuated to move the jaws from an open position to aclosed position, and at least one electrode configured to apply energyto tissue clamped between the jaws. The surgical system also includes acontrol system configured to actuate the closure assembly such that thejaws clamp the tissue with a first clamping force when the at least oneelectrode is not applying the energy to the tissue and such that thejaws clamp the tissue with a second clamping force when the at least oneelectrode is applying the energy to the tissue. The second clampingforce is higher than the first clamping force.

The surgical system can vary in any number of ways. For example, thesurgical system can include a tool driver operatively coupled to thecontrol system and configured to be removably and replaceablyoperatively coupled to the housing of the surgical tool. The tool drivercan include at least one motor, and the control system can be configuredto cause the at least one motor to drive the closure assembly. In atleast some embodiments, the control system and the tool driver can becomponents of a robotic surgical system.

For another example, the control system can be configured to causeenergy to be delivered to the at least one electrode such that the atleast one electrode can apply energy to the tissue clamped between thejaws. For yet another example, the control system can be a component ofa robotic surgical system, and the control system can be configured toactuate the closure assembly in response to a user input to the roboticsurgical system. For another example, the control system can include aprocessor. For yet another example, the control system can be configuredto actuate the closure assembly such that the jaws move toward theclosed position at a speed that varies based on a position of theclosure assembly relative to the jaws and based on the clamping forcethat the jaws clamp the tissue. For another example, the control systemcan be configured to actuate the closure assembly such that the jawsmove toward the closed position at a speed that varies based on an angleof the jaws relative to one another, and the speed can have an inverserelationship with the angle of the jaws. For still another example, theat least one electrode can include at least one electrode on the firstjaw and at least one electrode on the second jaw, and, in response tothe at least one electrode on the first jaw contacting the at least oneelectrode on the second jaw, the control system can be configured tocause tissue-facing surfaces of the jaws to be at a predeterminednon-zero distance relative to one another. For yet another example, theat least one electrode can include at least one electrode on the firstjaw and at least one electrode on the second jaw, the control system canbe configured to cause a short between the at least one electrode on thefirst jaw and the at least one electrode on the second jaw, and, inresponse to the short, the control system can be configured to cause thejaws to be at a predetermined angle relative to one another.

In another embodiment, a surgical system includes a drive systemconfigured to be removably and replaceably operatively coupled to asurgical tool configured to apply energy to tissue clamped by thesurgical tool. The drive system is configured to drive the applicationof energy. The surgical system also includes an electrosurgicalgenerator; and a control system configured to be operatively coupled tothe drive system. The control system is configured to receive energyfrom the generator, deliver the received energy from the generator tothe drive system to drive the application of energy, receive first datavia the drive system related to the application of the energy from thesurgical tool to the tissue, manipulate the first data to create seconddata that is modified from the first data, and transmit the second datato the generator to cause the generator to deliver energy to the controlsystem within predefined power parameters of the generator that define amaximum amount of energy the generator can deliver to the controlsystem. Transmitting the first data to the generator would prevent thegenerator from delivering energy to the control system as being outsidethe predefined power parameters of the generator.

The surgical system can have any number of variations. For example, thefirst data can include impedance of the tissue clamped by the surgicaltool. In at least some embodiments, the manipulation of the impedancedata can include processing with a processor the impedance data througha pair of transformers in parallel.

For another example, the drive system can include at least one motorconfigured to drive the surgical tool removably and replaceablyoperatively coupled to the drive system to drive the application ofenergy. For yet another example, a robotic surgical system can includethe drive system and the control system. For still another example, thesurgical tool can include first and second jaws configured to clamp thetissue, and each of the first and second jaws can have at least oneelectrode thereon that is configured to apply the energy to the clampedtissue. For yet another example, the energy can be radiofrequencyenergy.

In another embodiment, a surgical system includes an electrosurgicalgenerator having predefined power parameters that define a maximumamount of energy the generator can deliver therefrom, and a controlsystem configured to be operatively coupled to a surgical toolconfigured to apply energy to tissue clamped by the surgical tool. Thecontrol system is configured to receive data that is indicative of animpedance of tissue that is clamped by the surgical tool, transform thereceived data, transmit the transformed data to the generator so as tospoof the generator into delivering energy to the control system becausetransmission of the untransformed data to the generator prevent thegenerator from delivering energy to the control system as being outsideof the predefined power parameters of the generator, and, aftertransmitting the transformed data, receive energy from the generator.The control system is also configured to deliver the received energy tothe surgical tool to allow the surgical tool to apply energy to theclamped tissue.

The surgical system can vary in any number of ways. For example,transforming the data can include processing with a processor the datathrough a pair of transformers in parallel.

For another example, the surgical method can include a drive systemconfigured to drive the application of energy in response to controlfrom the control system. The drive system can be configured tooperatively couple to the surgical tool, and the drive system caninclude at least one motor configured to drive the surgical toolremovably and replaceably operatively coupled to the drive system todrive the application of energy. In at least some embodiments, a roboticsurgical system can include the drive system and the control system.

For yet another example, the surgical tool can include first and secondjaws configured to clamp the tissue, and each of the first and secondjaws can have at least one electrode thereon that is configured to applythe energy to the clamped tissue. For still another example, the energycan be radiofrequency energy.

In another embodiment, a surgical system includes a surgical toolincluding an elongate shaft, first and second jaws at a distal end ofthe elongate shaft, a housing at a proximal end of the elongate shaft, aclosure assembly disposed at least partially in the housing andconfigured to be actuated to move the jaws between an open position anda closed position, and at least two electrodes configured to applyenergy to tissue clamped between the jaws. The surgical system alsoincludes a control system configured to actuate the closure assembly tomove the jaws between the open position and the closed position, and,when the jaws are in the closed position, determine whether anelectrical parameter associated with the surgical tool is at or below apredetermined threshold value. The control system is also configured to,in response to the electrical parameter associated with the surgicaltool being determined to be at or below the predetermined thresholdvalue, actuate the closure assembly to cause the jaws to move from theclosed position toward the open position. The control system is alsoconfigured to determine if during the movement of the jaws from theclosed position toward the open position the electrical parameterchanged or remained substantially constant, receive an instruction todeliver energy to the at least two electrodes, and, in response to thereceived instruction, allow energy to be delivered to the at least twoelectrodes if it was determined that the electrical parameter remainedsubstantially constant during the movement of the jaws from the closedposition toward the open position, and prevent energy from beingdelivered to the at least two electrodes if it was determined that theelectrical parameter changed during the movement of the jaws from theclosed position toward the open position.

The surgical system can have any number of variations. For example, thesurgical system can include a tool driver operatively coupled to thecontrol system and configured to be removably and replaceablyoperatively connected to the housing of the surgical tool. The tooldriver can include at least one motor, and the control system can beconfigured to cause the at least one motor to drive the closureassembly. In at least some embodiments, the control system and the tooldriver can be components of a robotic surgical system.

For another example, the control system can be a component of a roboticsurgical system, and the control system can be configured to actuate theclosure assembly in response to a user input to the robotic surgicalsystem. For yet another example, the control system can include aprocessor. For still another example, the electrical parameter beingdetermined to have remained substantially constant can be indicative ofthe first and second jaws having tissue clamped therebetween, and theelectrical parameter being determined to have changed can be indicativeof a short of the at least two electrodes.

In another embodiment, a surgical system includes a surgical toolincluding an elongate shaft, an end effector at a distal end of theelongate shaft, and a housing at a proximal end of the elongate shaft.The end effector is configured to selectively deliver radiofrequencyenergy and ultrasound energy to tissue engaged by the end effector. Thesurgical system also includes a control system configured to cause theend effector to selectively deliver the radiofrequency energy and theultrasound energy to the tissue, and vary a force applied by the endeffector to the tissue engaged by the end effector based on whether thesurgical tool is operating in a first mode in which radiofrequencyenergy but not ultrasound energy is being delivered to the tissue, isoperating in a second mode in which both radiofrequency energy andultrasound energy are being applied to the tissue, and is operating in athird mode in which ultrasound energy but not radiofrequency energy isbeing applied to the tissue.

The surgical system can vary in any number of ways. For example, theforce applied by the end effector to the tissue can be greater in thefirst and third modes than in the second mode.

For another example, the surgical system can include a sensor configuredto sense impedance of the tissue engaged by the end effector, and thecontrol system can be configured to vary the force also based on thesensed impedance. In at least some embodiments, when the surgical toolis operating in the first mode, the control system can be configured toreduce the force in response to the sensed impedance decreasing and toincrease the force in response to the sensed impedance increasing.

For yet another example, the end effector can be configured to clamptissue, and the force can be a compressive force on the clamped tissue.In at least some embodiments, the surgical tool can include a closureassembly disposed at least partially in the housing and configured to beactuated to move the end effector between an open position and a closedposition, and the control system can be configured to vary the force byopening or closing the end effector.

For still another example, in the second mode more ultrasound energythan radiofrequency energy can be being applied to the tissue, thesurgical tool can be configured to operate in a fourth mode in whichboth radiofrequency energy and ultrasound energy are being applied tothe tissue and more radiofrequency energy than ultrasound energy isbeing applied to the tissue, and the control system can be configured tovary the force also based on whether the surgical tool is operating inthe fourth mode. For another example, the surgical tool operating in thefirst mode can cause coagulation of the tissue engaged by the endeffector, the surgical tool operating in the second mode can enhance thecoagulation, and the surgical tool operating in the third mode can causecutting of the tissue engaged by the end effector. For still anotherexample, the control system can include a processor.

For yet another example, the surgical system can include a tool driverof a robotic surgical system configured to operatively connect to thehousing, and the control system can be a component of the roboticsurgical system. In at least some embodiments, the tool driver caninclude at least one motor configured to drive the delivery of theradiofrequency energy, configured to drive the delivery of theultrasound energy, and configured to vary the force applied by the endeffector.

In another embodiment, a surgical system includes a surgical toolincluding an elongate shaft, an end effector at a distal end of theelongate shaft, a housing at a proximal end of the elongate shaft, and aclosure assembly disposed at least partially in the housing andconfigured to be actuated to move the end effector between an openposition and a closed position. The end effector is configured toselectively deliver radiofrequency energy and ultrasound energy totissue clamped by the end effector. The surgical system also includes asensor configured to sense impedance of the tissue engaged by the endeffector, a motor configured to drive the closure assembly, and acontrol system configured to control the motor to drive the actuation ofthe closure assembly such that the end effector applies a variablecompressive force to the tissue clamped thereby based on the sensedimpedance and based on whether both radiofrequency energy and ultrasoundenergy are currently being applied to the tissue clamped by the endeffector or only one of radiofrequency energy and ultrasound energy iscurrently being applied to the tissue clamped by the end effector.

The surgical system can have any number of variations. For example, thecompressive force can be less when both radiofrequency energy andultrasound energy are currently being applied than when only one ofradiofrequency energy and ultrasound energy is currently being applied.In at least some embodiments, when both radiofrequency energy andultrasound energy are currently being applied, the compressive force canbe less when more ultrasound energy than radiofrequency energy iscurrently being applied than when more radiofrequency energy thanultrasound energy is currently being applied.

For another example, the sensed impedance can be indicative of whetherboth radiofrequency energy and ultrasound energy are currently beingapplied or only one of radiofrequency energy and ultrasound energy iscurrently being applied. For yet another example, when only one ofradiofrequency energy and ultrasound energy is currently being applied,the control system can be configured to reduce the compressive force inresponse to the sensed impedance decreasing and is configured toincrease the compressive force in response to the sensed impedanceincreasing. For still another example, the surgical system can include atool driver assembly configured to be operatively connected to thehousing, the tool driver assembly can include the motor, and the tooldriver assembly and the control system can be components of a roboticsurgical system. For yet another example, the surgical tool can includeat least two electrodes configured to apply the radiofrequency energy tothe tissue. For another example, the control system can include aprocessor.

In another aspect, a surgical method is provided that in on embodimentincludes actuating a drive system of a robotic surgical system to causea pair of jaws of a surgical tool to clamp tissue therebetween with aclamping force. The surgical tool is removably and replaceablyoperatively connected to the drive system. The surgical method alsoincludes actuating the drive system to cause energy to be delivered tothe tissue clamped between the jaws, and, in response to the actuationof the drive system to cause the energy to be delivered, causing thepair of jaws to clamp the tissue therebetween with an increased clampingforce.

The surgical method can vary in any number of ways. For example, therobotic surgical system can include a control system configured toreceive a first input from a user requesting that the pair of jaws clampthe tissue. The control system can be configured to receive a secondinput from a user requesting that the energy be delivered to the tissueclamped between the jaws. The surgical method can further include, inresponse to receiving the first input, the control system actuates thedrive system to cause the pair of jaws to clamp the tissue therebetweenwith the clamping force. The surgical method can further include, inresponse to receiving the second input, the control system actuates thedrive system to cause the energy to be delivered and cause the pair ofjaws to clamp the tissue therebetween with the increased clamping force.The control system can include a processor.

For another example, the drive system can include at least one motorthat drives the clamping of the pair of jaws and that drives theapplication of the energy.

For yet another example, the energy can be delivered to the tissue by atleast one electrode on one of the jaws and at least one electrode on theother of the jaws. In at least some embodiments, the surgical method caninclude, in response to the at least one electrode on the first jawcontacting the at least one electrode on the second jaw, causingtissue-facing surfaces of the jaws to be at a predetermined non-zerodistance relative to one another. In at least some embodiments, thesurgical method can include causing a short between the at least oneelectrode on the first jaw and the at least one electrode on the secondjaw, and, in response to the short, causing the jaws to be at apredetermined angle relative to one another.

For still another example, actuating the drive system to cause the pairof jaws to clamp the tissue therebetween can include moving the jaws ata speed from an open position toward a closed position, and the speedcan vary based on a position of a closure assembly of the surgical toolrelative to the jaws and based on the clamping force. For anotherexample, actuating the drive system to cause the pair of jaws to clampthe tissue therebetween can include moving the jaws at a speed from anopen position toward a closed position, the speed can vary based on anangle of the jaws relative to one another, and the speed can have aninverse relationship with the angle of the jaws.

In another embodiment, a surgical method includes actuating a drivesystem of a robotic surgical system to cause a pair of jaws of asurgical tool to clamp tissue therebetween with a clamping force thatdoes not exceed a predetermined maximum force. The surgical tool isremovably and replaceably operatively connected to the drive system. Thesurgical method also includes actuating the drive system to cause energyto be delivered to the tissue clamped between the jaws, and, in responseto the actuation of the drive system to cause the energy to bedelivered, increasing the clamping force above the predetermined maximumforce such that a distance between tissue-facing surfaces of the jaws isreduced. The surgical method can have any number of variations.

In another embodiment, a surgical method includes receiving at a controlsystem of a robotic surgical system data indicative of an impedance oftissue that is clamped by a surgical tool operatively coupled to thecontrol system, transforming the received data at the control system,transmitting the transformed data from the control system to anelectrosurgical generator operatively coupled to the control system, andreceiving energy at the control system from the electrosurgicalgenerator. The generator is configured such that the generator candeliver energy to the control system based on the transformed data andsuch that operating parameters of the generator prevent from deliveringenergy to the control system based on the untransformed data. Thesurgical method also includes delivering the received energy from thecontrol system to the surgical tool such that the surgical tool appliesthe energy to the clamped tissue.

The surgical method can have any number of variations. For example,transforming the received data at the control system can includeprocessing with a processor the received data through a pair oftransformers in parallel. For another example, the control system canreceive the data via a drive system of the robotic surgical system, andthe drive system can be controlled by the control system and can includeat least one motor that drives the application of the energy to theclamped tissue. For still another example, the surgical tool can includefirst and second jaws configured to clamp the tissue, and each of thefirst and second jaws can have at least one electrode thereon thatapplies the energy to the clamped tissue. For another example, theenergy can be radiofrequency energy.

In another embodiment, a surgical method includes monitoring with acontrol system of a robotic surgical system an electrical parameterassociated with a surgical tool that has first and second jaws thereofin a clamped position. The robotic surgical system includes a tooldriver that is operatively coupled to the surgical tool, the first jawhas a first electrode thereon, and the second jaw has a second electrodethereon. The surgical method also includes, in response to theelectrical parameter being at or below a predetermined threshold value,causing the tool driver to drive the surgical tool such that a gapbetween facing surfaces of the first and second jaws increases. Thesurgical method also includes, during the increasing of the gap,determining with the control system whether the electrical parameter ischanging or is remaining substantially constant. The surgical methodalso includes, in response to the electrical parameter being determinedto be remaining substantially constant, allowing energy to be deliveredto the first and second electrodes. The surgical method also includes,in response to the electrical parameter being determined to be changing,preventing energy from being delivered to the first and secondelectrodes.

The surgical method can vary in any number of ways. For example, theelectrical parameter can include impedance, and the monitoring caninclude sensing the impedance using a sensor. For another example, theelectrical parameter can include current of a motor of the tool driver,and the motor can have driven the surgical tool to the clamped position.For yet another example, the electrical parameter being determined to beremaining substantially constant can be indicative of the first andsecond jaws having tissue clamped therebetween, and the electricalparameter being determined to be changing can be indicative of a shortof the first and second electrodes. For another example, the tool drivercan drive the surgical tool such that the gap between facing surfaces ofthe first and second jaws increases to a predetermined maximum gap.

For still another example, the surgical method can include, after theincreasing of the gap, causing the tool driver to drive the surgicaltool such that the gap between facing surfaces of the first and secondjaws decreases. In at least some embodiments, causing the tool driver todrive the surgical tool such that the gap between facing surfaces of thefirst and second jaws decreases can occur prior to either allowingenergy to be delivered to the first and second electrodes or preventingenergy from being delivered to the first and second electrodes.

For another example, the control system can be configured to cause thetool driver to drive the delivery of the energy to the first and secondelectrodes. For yet another example, the control system can cause atleast one motor of the tool driver to drive the surgical tool such thatthe gap increases. For still another example, the control system caninclude a processor.

In another embodiment, a surgical method includes actuating a surgicaltool to cause first and second jaws of the surgical tool to move from anopen position toward a closed position. The first jaw has a firstelectrode thereon, and the second jaw has a second electrode thereon.The surgical method also includes, during the movement of the jaws,monitoring an electrical parameter associated with the surgical tool.The surgical method also includes, in response to the electricalparameter dropping to a predetermined threshold value, actuating thesurgical tool again to cause the first and second jaws to move towardthe open position, determining if during the movement of the first andsecond jaws toward the open position the electrical parameter remainssubstantially constant. In response to determining that the electricalparameter remains substantially constant, energy is allowed to bedelivered to the first and second electrodes. In response to determiningthat the electrical parameter does not remain substantially constant,energy is prevented from being delivered to the first and secondelectrodes.

The surgical method can have any number of variations. For example, theelectrical parameter can include impedance, and the monitoring caninclude sensing the impedance using a sensor. For another example, theelectrical parameter can include current of a motor of the tool driver,and the motor can drive the surgical tool to move the first and secondjaws from the open position toward the closed position. For yet anotherexample, the electrical parameter being determined to be remainingsubstantially constant can be indicative of the first and second jawshaving tissue clamped therebetween, and the electrical parameter beingdetermined to be changing can be indicative of a short of the first andsecond electrodes.

For another example, actuating the surgical tool can include a controlsystem of a robotic surgical system causing a tool driver of the roboticsurgical system to drive the first and second jaws to move from the openposition toward the closed position, and the tool driver can beremovably and replaceably coupled to a housing of the surgical tool. Inat least some embodiments, the control system can determine if duringthe movement of the first and second jaws toward the open position theelectrical parameter remains substantially constant, and the controlsystem, in response to determining that the electrical parameter remainssubstantially constant, can allow energy to be delivered to the firstand second electrodes, and the control system, in response todetermining that the electrical parameter does not remain substantiallyconstant, can prevent energy from being delivered to the first andsecond electrodes. In at least some embodiments, the surgical method caninclude, after the determining, receiving at the control system aninstruction to deliver energy to the first and second electrodes, and,in response to determining that the electrical parameter remainssubstantially constant, the control system can allow the energy to bedelivered to the first and second electrodes, and, in response todetermining that the electrical parameter does not remain substantiallyconstant, the control system can prevent the energy from being deliveredto the first and second electrodes. In at least some embodiments, atleast one motor of the tool driver can drive the first and second jawsto move from the open position toward the closed position. In at leastsome embodiments, the control system can include a processor.

In another embodiment, a surgical method includes actuating a tooldriver of a robotic surgical system with a control system of the roboticsurgical system to cause an end effector of a surgical tool to grasptissue such that the end effector applies a force to the tissue. Thesurgical tool is operatively connected to the tool driver. The surgicalmethod also includes actuating the tool driver with the control systemto cause the surgical tool to apply energy to the grasped tissue suchthat radiofrequency energy, but not ultrasound energy, is applied to thegrasped tissue and then both radiofrequency energy and ultrasound energyare applied to the grasped tissue. The surgical method also includescausing with the control system the force applied to the tissue todecrease in response to both radiofrequency energy and ultrasound energybeing applied to the grasped tissue.

The surgical method can have any number of variations. For example,actuating the tool driver can also cause ultrasound energy, but notradiofrequency energy, to be applied to the grasped tissue after theradiofrequency energy and ultrasound energy are both applied to thegrasped tissue, and the surgical method can also include causing withthe control system the force applied to the tissue to increase inresponse to ultrasound energy, but not radiofrequency energy, beingapplied to the grasped tissue. For another example, the application ofradiofrequency energy without the application of ultrasound energy cancause coagulation of the grasped tissue, the application of bothradiofrequency energy and ultrasound energy can enhance the coagulation,and the application of ultrasound energy without the application ofradiofrequency energy can cut the grasped tissue.

BRIEF DESCRIPTION OF DRAWINGS

This invention will be more fully understood from the following detaileddescription taken in conjunction with the accompanying drawings, inwhich:

FIG. 1 is a perspective view of a portion of one embodiment of anelectrosurgical tool;

FIG. 2 is a perspective view of the tool of FIG. 1 coupled to agenerator;

FIG. 3 is a perspective view of a distal portion of the tool of FIG. 1with an end effector thereof open;

FIG. 4 is a perspective view of a distal portion of the tool of FIG. 1with the end effector thereof closed;

FIG. 5 is a perspective view of a proximal portion of the tool of FIG.1;

FIG. 6 is a top view of a proximal portion of the tool of FIG. 1;

FIG. 7 is a perspective view of a portion of another embodiment of anelectrosurgical tool;

FIG. 8 is a perspective view of a distal portion of another embodimentof an electrosurgical tool;

FIG. 9 is an exploded view of a distal portion of the tool of FIG. 8;

FIG. 10 is a side cross-sectional view of a distal portion of the toolof FIG. 8 with an end effector thereof open;

FIG. 11 is a side cross-sectional view of a distal portion of the toolof FIG. 8 with an end effector thereof closed;

FIG. 12 is a perspective view of a distal portion of another embodimentof an electrosurgical tool;

FIG. 13 is another perspective view of a distal portion of the tool ofFIG. 12;

FIG. 14 is a side view of an intermediate portion of the tool of FIG.12;

FIG. 15 is yet another perspective view of a distal portion of the toolof FIG. 12;

FIG. 16 is an exploded view of a proximal portion of the tool of FIG.12;

FIG. 17 is a perspective view of a proximal portion of the tool of FIG.12;

FIG. 18 is a perspective view of another embodiment of a proximalportion of an electrosurgical tool;

FIG. 19 is a schematic view of one embodiment of a robotic surgicalsystem;

FIG. 20 is a graph illustrating motor current, cutting element velocity,impedance, and power versus time;

FIG. 21 is a side transparent view of an intermediate portion of anotherembodiment of an electrosurgical tool;

FIG. 22 is a perspective view of a distal portion of another embodimentof an electrosurgical tool;

FIG. 23 is a side transparent view of a distal portion of still anotherembodiment of an electrosurgical tool;

FIG. 24 is a flowchart of one embodiment of a process of controllingspeed of an electrosurgical tool's cutting element;

FIG. 25 is a graph illustrating clamp force, tissue gap, power, andimpedance over time;

FIG. 26 is a table illustrating electrosurgical tool functions invarious stages of operation illustrated in FIG. 25;

FIG. 27 is a graph illustrating impedance, tissue gap, and power overtime;

FIG. 28 is a graph illustrating velocity, force, and jaw angle overtime;

FIG. 29 is another graph illustrating impedance, tissue gap, and powerover time;

FIG. 30 is a graph illustrating impedance and force over time;

FIG. 31 is a schematic view of one embodiment of a control systemoperatively coupled to a generator and an electrosurgical tool;

FIG. 32 is a schematic view of another embodiment of a control systemoperatively coupled to a generator and an electrosurgical tool;

FIG. 33 is a table illustrating modes of processing of the controlsystem of FIG. 32;

FIG. 34 is a schematic view of a surgical system including a controlsystem operatively coupled to a generator and an electrosurgical tool;

FIG. 35 is a graph illustrating power versus impedance for the surgicalsystem of FIG. 34; and

FIG. 36 illustrates one exemplary embodiment of a computer system thatcan be used to implement a control system of the present disclosure.

DETAILED DESCRIPTION

Certain exemplary embodiments will now be described to provide anoverall understanding of the principles of the structure, function,manufacture, and use of the devices and methods disclosed herein. One ormore examples of these embodiments are illustrated in the accompanyingdrawings. Those skilled in the art will understand that the devices andmethods specifically described herein and illustrated in theaccompanying drawings are non-limiting exemplary embodiments and thatthe scope of the present invention is defined solely by the claims. Thefeatures illustrated or described in connection with one exemplaryembodiment may be combined with the features of other embodiments. Suchmodifications and variations are intended to be included within thescope of the present invention.

Further, in the present disclosure, like-named components of theembodiments generally have similar features, and thus within aparticular embodiment each feature of each like-named component is notnecessarily fully elaborated upon. Additionally, to the extent thatlinear or circular dimensions are used in the description of thedisclosed systems, devices, and methods, such dimensions are notintended to limit the types of shapes that can be used in conjunctionwith such systems, devices, and methods. A person skilled in the artwill recognize that an equivalent to such linear and circular dimensionscan easily be determined for any geometric shape. Sizes and shapes ofthe systems and devices, and the components thereof, can depend at leaston the anatomy of the subject in which the systems and devices will beused, the size and shape of components with which the systems anddevices will be used, and the methods and procedures in which thesystems and devices will be used.

It will be appreciated that the terms “proximal” and “distal” are usedherein with reference to a user, such as a clinician, gripping a handleof an instrument. Other spatial terms such as “front” and “rear”similarly correspond respectively to distal and proximal. It will befurther appreciated that for convenience and clarity, spatial terms suchas “vertical” and “horizontal” are used herein with respect to thedrawings. However, surgical instruments are used in many orientationsand positions, and these spatial terms are not intended to be limitingand absolute.

Various exemplary methods, systems, and devices for controllingelectrosurgical tools are provided. In general, an electrosurgical toolis configured to apply energy to tissue, such as via an end effector ofthe surgical tool. The energy can include one or more types of energy,such as electrical energy, ultrasonic energy, and heat energy. Theelectrical energy can be a high frequency alternating current such asradiofrequency (RF) energy, or can be another type of electrical energy.

An exemplary electrosurgical tool can include a variety of features tofacilitate application of energy as described herein. However, a personskilled in the art will appreciate that the electrosurgical tools caninclude only some of these features and/or can include a variety ofother features known in the art. The electrosurgical tools describedherein are merely intended to represent certain exemplary embodiments.Further, a person skilled in the art will appreciate that theelectrosurgical tools described herein have application in conventionalminimally-invasive and open surgical instrumentation as well asapplication in robotic-assisted surgery.

In an exemplary embodiment, an electrosurgical tool includes an elongateshaft, an end effector at a distal end of the elongate shaft, and ahousing at a proximal end of the elongate shaft. The housing includes adrive system configured to operably couple to at least one motor fordriving the drive system to cause performance of various functions ofthe surgical tool. The housing can be configured to be handheld andmanually actuated by a user to actuate the drive system, or the housingcan be configured to be operatively couple to a robotic surgical systemconfigured to actuate the drive system. The at least one motor can beincluded as part of the electrosurgical tool, such as by being locatedin the housing, or the at least one motor can be separate andindependent of the electrosurgical tool, such as the at least one motorbeing included in a tool housing of a robotic surgical system. The drivesystem is configured to operably couple to a control system configuredto operably couple to the at least one motor. The control system can beincluded as part of the electrosurgical tool, such as by being locatedin the housing, or the control system can be separate and independent ofthe electrosurgical tool, such as the control system being included in arobotic surgical system. The control system is configured to actuate theat last one motor to thereby control actuation of the drive system.

FIGS. 1 and 2 illustrate one embodiment of an electrosurgical tool 100.The tool 100 includes an elongate shaft 102, an end effector 104 coupledto a distal end of the shaft 102, and a proximal housing portion 106including a housing 110 coupled to a proximal end of the shaft 102. Forclarity of illustration, a portion of the housing 110 is omitted inFIG. 1. The end effector 104 in this illustrated embodiment includesfirst and second jaw members 108 a, 108 b, also referred to herein as“jaws,” and is configured to move between an open position and a closedposition. The end effector 104 is shown in the open position in FIGS. 1and 2. The first and second jaw members 108 a, 108 b are straight, butin other embodiments the jaws can be curved. The jaw members 108 a, 108b are configured to close to thereby capture or engage tissue so as toclamp or grasp the tissue therebetween. The first and second jaw members108 a, 108 b can apply compression to the clamped tissue.

One or both of the jaw members 108 a, 108 b includes an electrode forproviding electrosurgical energy to tissue. In an exemplary embodiment,each of the jaws 108 a, 108 b includes at least one electrode, e.g., thetool 100 is bipolar, such that electrical current can flow between theelectrodes in the opposing jaw members 108 a, 108 b and through tissuepositioned therebetween. In this illustrated embodiment, as shown inFIG. 3, the first jaw 108 a has an electrode 112 a on a tissue-facingsurface thereof and the second jaw 108 b has an electrode 112 b on atissue-facing surface thereof. The electrodes 112 a, 112 b areconfigured to be positioned against and/or positioned relative to tissuesuch that electrical current can flow through the tissue. The electricalcurrent may generate heat in the tissue that, in turn, causes one ormore hemostatic seals to form within the tissue and/or between tissues.For example, tissue heating caused by the electrical current may atleast partially denature proteins within the tissue. Such proteins, suchas collagen, may be denatured into a proteinaceous amalgam thatintermixes and fuses, or “coagulates” or “welds,” together as theproteins renature. As the treated region heals over time, thisbiological “weld” may be reabsorbed by the body's wound healing process.As mentioned above, the energy applied can include high frequencyalternating current such as RF energy. When applied to tissue, RF energymay cause ionic agitation or friction, increasing the temperature of thetissue. Various embodiments of applying RF energy are described furtherin U.S. Patent Publication No. 2012/0078139 entitled “Surgical GeneratorFor Ultrasonic And Electrosurgical Devices” filed Oct. 3, 2011, U.S.Patent Publication No. 2012/0116379 entitled “Motor DrivenElectrosurgical Device With Mechanical And Electrical Feedback” filedJun. 2, 2011, and U.S. Patent Publication No. 2015/0209573 entitled“Surgical Devices Having Controlled Tissue Cutting And Sealing” filedJan. 28, 2014, which are hereby incorporated by reference in theirentireties.

As in this illustrated embodiment, as shown in FIG. 3, the tool 100 caninclude a cutting element 114, which is a knife on an I-beam 116 in thisillustrated embodiment. The cutting element 114 is configured totranslate along the end effector 104 and to cut or transect tissuepositioned between the jaws 108 a, 108 b. The cutting can occur duringor after the application of electrosurgical energy. The cutting element114 is shown in FIG. 3 in a start position, e.g., a proximal-mostposition of the cutting element 114, before the cutting element 114 hasbegun to translate along the end effector 104. FIG. 4 shows the cuttingelement 114 advanced a distance distally along the end effector 104,which is shown in the closed position. In the closed position, the jaws108 a, 108 b define a gap or dimension D between the tissue-facingsurfaces thereof. In various embodiments, the dimension D can be in arange from about 0.0005″ to about 0.040″, for example, and in someembodiments, in a range of about 0.001″ to about 0.010″, for example.

Distal and proximal translation of the I-beam 116 along the end effector114 is configured to open and close the jaw members 108 a, 108 b andthus when translating distally to cut, with the cutting element 114,tissue held between the jaw members 108 a, 108 b. In general, the I-beam116 is a beam having an “I” cross-sectional shape.

The tool 100 is configured to operatively couple with a generator 118,as shown in FIG. 2 in which the tool 100 is operatively coupled with thegenerator 118. The tool 100 is connected to the generator 118 with acable 120 in this illustrated embodiment but can connect thereto inother ways, as will be appreciated by a person skilled in the art. Thegenerator 118 is configured as an energy source, e.g., an RF source, anultrasonic source, a direct current source, etc., to deliver energy tothe tool 100 to allow the electrodes 112, 112 b to apply energy totissue. As in this illustrated embodiment, the generator 118 can becoupled to a controller, such as a control unit. The control unit can beformed integrally with the generator 118 or can be provided as aseparate and independent device electrically coupled to the generator118 (shown in phantom in FIG. 2 to illustrate this option). The controlunit is configured to regulate the energy delivered by generator 118which in turn delivers energy to the first and second electrodes 112 a,112 b. The energy delivery may be initiated in any suitable manner. Inone embodiment, the electrosurgical tool 100 can be energized by thegenerator 118 via actuation of a foot switch. When actuated, the footswitch (or other actuated actuator) triggers the generator 118 todeliver energy to the end effector 104. The control unit can beconfigured to regulate the power generated by the generator 118, asdiscussed for example further below. As also discussed further below,the control unit as a separate and independent device from the generator118 can be part of a robotic surgical system.

The generator 118 is shown separate and independent from the tool 100 inthis illustrated embodiment, but in other embodiments the generator 118(and/or the control unit) can be formed integrally with the tool 100 toform a unitary electrosurgical system. For example, a generator orequivalent circuit can be present at the proximal housing portion 106within the housing 110.

Various configurations of electrodes and various configurations forcoupling electrodes to the generator 118 are possible. As in thisillustrated embodiment, the first and second electrodes 112 a, 112 b canbe configured to be in electrical communication with the generator 118.The first electrode 112 a on the first jaw member 108 can be configuredto provide a return path for energy. In the illustrated embodiment andin functionally similar embodiments, other conductive parts of the tool100 including, for example the jaw members 108 a, 108 b, the shaft 102,etc. may form all or a part of the return path. Also, it will beappreciated by a person skilled in the art that the supply electrode canbe provided on the second jaw member 108 b as shown or can be providedon the first jaw member 108 a with the return electrode on the secondjaw member 108 b.

The proximal housing portion 106, e.g., within the housing 110, includesa drive system configured to operably couple to at least one motor fordriving the drive system to cause performance of various functions ofthe tool 100, such as closing of the jaws 108 a, 108 b, opening of thejaws 108 a, 108 b, articulating the end effector 104 relative to theshaft 102, rotating the shaft 102 about a longitudinal axis thereof,movement of the cutting element 114 along the end effector 104, andapplication of energy. As shown in FIGS. 1, 5, and 6, the tool 100includes a drive system that includes a first drive system 122configured to drive rotation of the shaft 102 (and thus also the endeffector 104 at the shaft's distal end) about the shaft's longitudinalaxis relative to the proximal housing portion 106, a second drive system124 configured to drive rotation of the end effector 104 about theshaft's longitudinal axis relative to the shaft 102 and the proximalhousing portion 106, a third drive system 126 configured to drivearticulation of the end effector 104 in opposed first and seconddirections FD, SD relative to the shaft's longitudinal axis, a fourthdrive system 128 configured to drive articulation of the end effector104 in opposed third and fourth directions TD, FTHD relative to theshaft's longitudinal axis, and a fifth drive system 130 configured todrive a closure assembly to selectively cause opening and closing of theend effector 104. The third and fourth drive systems 126, 128 togetherdefine an articulation drive system. In an exemplary embodiment, each ofthe drive systems 122, 124, 126, 128, 130 is configured to have onemotor operatively coupled thereto such that a rotary output motion fromits associated motor drives the drive system.

The first drive system 122 is configured to receive a rotary outputmotion from a motor, e.g., a motor of a tool driver of a roboticsurgical system when the tool driver is operatively coupled to the tool100 via the proximal housing portion 106, and convert the rotary outputmotion to a rotary control motion to be applied to cause the rotation ofthe shaft 102 (and the end effector 104). The first drive system 122includes a first rotation gear 134 formed on or attached to the shaft102 that has a proximal end thereof rotatably support of a tool mountingplate 136 at the proximal housing portion 106, a second rotation gear138 operatively engaged with the first rotation gear 134, a thirdrotation gear 140 operatively engaged with the second rotation gear 138,and a fourth rotation gear 142 operatively engaged with the thirdrotation gear 140. The fourth rotation gear 142 is operatively coupledto the motor such that the rotary output motion from the motor causesrotation of the fourth rotation gear 142 and, through the other threerotations gears 134, 138, 140, ultimately of the shaft 102 (and endeffector 104).

The second drive system 124 is configured to receive a rotary outputmotion from a motor, e.g., a motor of a tool driver of a roboticsurgical system when the tool driver is operatively coupled to the tool100 via the proximal housing portion 106, and convert the rotary outputmotion to a rotary control motion to be applied to the end effector 104to cause the rotation of the end effector 104. The second drive system124 includes a first rotary gear 144, a second rotary gear 146 that isoperatively engaged with the first rotary gear 144 and is rotatablysupported on the tool mounting plate 136, a third rotary gear 148 thatis selectively operatively engageable with the second rotary gear 146via a shifting mechanism 150. The first rotary gear 144 is operativelycoupled to the motor such that the rotary output motion from the motorcauses rotation of the first rotary gear 144 and, through the other tworotary gears 146, 148 when operatively engaged with one another,ultimately of the end effector 104.

FIG. 7 illustrates another embodiment of a second drive systemconfigured to receive a rotary output motion from a motor 152 on boardthe tool 100 (e.g., within the housing 110) and convert the rotaryoutput motion to a rotary control motion to be applied to the endeffector 104 to cause the rotation of the end effector 104. Sucharrangement can generate higher rotary output motions and torque, whichmay be advantageous when different forms of end effectors are employed.In this illustrated embodiment, the motor 152 is attached to the toolmounting plate 136 by a support structure 154 such that a driver gear(obscured by the support structure 154 in FIG. 7) that is coupled to themotor 152 is operatively engaged with the third rotary gear 148. Asillustrated, the motor 152 is battery powered. In such an arrangement,the motor 152 is configured to be operatively coupled to a controlsystem of a robotic surgical system 10 that controls the activation ofthe motor 152. In other embodiments, the motor 152 can be configured tobe manually actuatable by an on/off switch (not shown) mounted on themotor 152 itself or on the proximal housing portion 106. In still otherembodiments, the motor 152 can be configured to receive power andcontrol signals from the robotic surgical system.

Referring again to FIGS. 1, 5, and 6, the third drive system 126 isconfigured to receive a rotary output motion from a motor, e.g., a motorof a tool driver of a robotic surgical system when the tool driver isoperatively coupled to the tool 100 via the proximal housing portion106, and convert the rotary output motion to a rotary control motion tobe applied to the end effector 104 to selectively cause the articulationof the end effector 104 in the first and second directions FD, SD. Thethird drive system 126 includes a drive pulley 156 operatively engagedwith a drive cable 158 that extends around a drive spindle assembly 160that is pivotally mounted to the tool mounting plate 136. A tensionspring 162 is attached between the drive spindle assembly 160 and thetool mounting plate 136 to maintain a desired amount of tension in thedrive cable 158. A first end portion 158 a of the drive cable 158extends around an upper portion of a pulley block 164 that is attachedto the tool mounting plate 136, and a second end portion 158 b of thedrive cable 158 extends around a sheave pulley or standoff on the pulleyblock 164. Application of a rotary output motion from the motor in afirst direction will result in the rotation of the drive pulley 156 in afirst direction and cause the cable end portions 158 a, 158 b to move inopposite directions to apply control motions to the end effector 104 orelongate shaft 102. That is, when the drive pulley 156 is rotated in afirst rotary direction, the first cable end portion 158 a moves in adistal direction DD and the second cable end portion 158 b moves in aproximal direction PD. Rotation of the drive pulley 156 in an oppositerotary direction in response to a rotary output motion from the motor ina second direction (which is opposite to the first direction) results inthe first cable end portion 158 a moving in the proximal direction PDand the second cable end portion 158 b moving in the distal directionDD. The end effector 104 can thus be selectively articulated in theopposed first and second directions FD, SD based on the direction of themotor's rotary output motion.

The fourth drive system 128 is configured to receive a rotary outputmotion from a motor, e.g., a motor of a tool driver of a roboticsurgical system when the tool driver is operatively coupled to the tool100 via the proximal housing portion 106, and convert the rotary outputmotion to a rotary control motion to be applied to the end effector 104to cause the articulation of the end effector 104 in the third directionTD. The fourth drive system 128 includes a drive pulley 166 operativelyengaged with a drive cable 168 that extends around a drive spindleassembly 170 that is pivotally mounted to the tool mounting plate 136. Atension spring 172 is attached between the drive spindle assembly 170and the tool mounting plate 136 to maintain a desired amount of tensionin the drive cable 168. A first cable end portion 168 a of the drivecable 168 extends around a bottom portion of the pulley block 164, and asecond cable end portion 168 b extends around a sheave pulley orstandoff 173 on the pulley block 164. Application of a rotary outputmotion from the motor in one direction will result in the rotation ofthe drive pulley 166 in one direction and cause the cable end portions168 a, 168 b to move in opposite directions to apply control motions tothe end effector 104 or elongate shaft 102. That is, when the drivepulley 166 is rotated in a first rotary direction, the first cable endportion 168 a moves in the distal direction DD and the second cable endportion 168 b moves in the proximal direction PD. Rotation of the drivepulley 166 in an opposite rotary direction result in the first cable endportion 168 a moving in the proximal direction PD and the second cableend portion 168 b to move in the distal direction DD. The end effector104 can thus be selectively articulated in the opposed third and fourthdirections TD, FTHD based on the direction of the motor's rotary outputmotion.

The fifth drive system 130 is configured to axially displace the closureassembly. The closure assembly includes a proximal drive rod segment 174that extends through a proximal drive shaft segment 132 and a driveshaft assembly 176. A distal end of the proximal drive rod segment 174is operatively coupled to a proximal end of the I-beam 116, eitherthrough direct connection or through indirect connection via one or moreintermediate drive rod segments. A movable drive yoke 178 is slidablysupported on the tool mounting plate 136. The proximal drive rod segment174 is supported in the drive yoke 178 and has a pair of retainer balls180 thereon such that shifting of the drive yoke 178 on the toolmounting plate 136 results in the axial movement of the proximal driverod segment 174. A drive solenoid 182 operably couples with the driveyoke 178 and is configured to receive control power from the controlsystem. Actuation of the drive solenoid 182 in a first direction willcause the closure assembly, e.g., the I-beam 116 and the proximal driverod segment 174, to move in the distal direction DD and actuation of thedrive solenoid 182 in a second direction will cause the closureassembly, e.g., the I-beam 116 and the proximal drive rod segment 174 tomove in the proximal direction PD. The end effector 104 can thus beselectively opened (movement of the proximal drive rod segment 174 inone direction) and closed (movement of the proximal drive rod segment inthe opposite direction).

FIGS. 8-11 illustrate another embodiment of an electrosurgical tool 200.The tool 200 is generally configured and used similar to the tool 100 ofFIG. 1 and includes an elongate shaft 202, an end effector 204 coupledto a distal end of the shaft 202 and including first and second jaws 206a, 206 b, at least one electrode at the end effector 204, a proximalhousing portion (not shown) including a drive system and including ahousing coupled to a proximal end of the shaft 202, an I-beam 208, and acutting element 210. Similar to the proximal housing portion 106 of FIG.1 discussed above, the proximal housing portion of the tool 200 can beconfigured to operably couple to a tool driver of a robotic surgicalsystem, or the proximal housing portion can be configured to be handheldand operated manually. It will be appreciated by a person skilled in theart that the tool 200 can contain and/or can be configured tooperatively connect to a generator for generating an electrosurgicaldrive signal to drive the tool's drive system, which as discussed abovecan include multiple drive systems.

The tool 200 also has a closure assembly configured and used similar tothe closure assembly of the tool 100 of FIG. 1. In this illustratedembodiment, the closure assembly includes the I-beam 208, a rotary drivemember 222 that extends proximally from the I-beam 208, and a rotarydrive shaft 212 movably disposed in the elongate shaft 202 andoperatively coupled to the rotary drive member 222. The rotary driveshaft 212 is operatively coupled to a drive system of the tool that isconfigured to drive the closure assembly, e.g., by a motor operativelycoupled to the drive system providing rotational and axial translationalmotion to the rotary drive shaft 212.

The I-beam 208 has a first I-beam flange 214 a and a second I-beamflange 214 b that are connected with an intermediate portion 216. Thecutting element 210 is a distal-facing sharp edge or blade on theintermediate portion 216 of the I-beam 208 in this illustratedembodiment. The I-beam 208 is configured to translate within a firstchannel 218 a in the first jaw member 206 a, e.g., with the first flange214 a moving within the first channel 218 a, and within a second channel218 b in the second jaw member 206 b, e.g., with the second flange 214 bmoving within the second channel 218 b. As the I-beam 208 is advanceddistally, the first jaw 206 a is moved toward the second jaw 206 b tomove the end effector 204 to the closed position. FIGS. 8 and 10 showthe end effector 204 in the open position and show the I-beam 208 andcutting element 210 in their start or proximal-most positions. FIG. 11shows the end effector 204 in the closed position and show the I-beam208 and cutting element 210 in their end or distal-most positions. Aftera distal translation stroke, the I-beam 208 and the cutting element 210can be proximally refracted back to their start positions, which willmove the end effector 204 from the closed position to the open position.

As shown in FIGS. 9-11, a threaded rotary drive nut 220 is threaded ontothe rotary drive member 222. The threaded rotary drive nut 220 is seatedin the second jaw 206 b. The threaded rotary drive nut 220 ismechanically constrained from translation in any direction, but thethreaded rotary drive nut 220 is rotatable within the second jaw 206 b.Therefore, given the threaded engagement of the rotary drive nut 220 andthe threaded rotary drive member 222, rotational motion of the rotarydrive nut 220 is transformed into translational motion of the threadedrotary drive member 222 in the longitudinal direction and, in turn, intotranslational motion of the I-beam 208, and hence the cutting element210, in the longitudinal direction.

The threaded rotary drive member 222 is threaded through the rotarydrive nut 220 and is located inside a lumen of the rotary drive shaft212. The threaded rotary drive member 222 is not attached or connectedto the rotary drive shaft 212. The threaded rotary drive member 222 isfreely movable within the lumen of the rotary drive shaft 212 and isconfigured to translate within the lumen of the rotary drive shaft 212when driven by rotation of the rotary drive nut 220.

The rotary drive shaft 212 a rotary drive head 224. The rotary drivehead 224 has a female hex coupling portion 226 on a distal side of therotary drive head 224, and the rotary drive head 224 has a male hexcoupling portion 228 on a proximal side of the rotary drive head 224.The distal female hex coupling portion 226 of the rotary drive head 224is configured to mechanically engage with a male hex coupling portion230 of the rotary drive nut 220 located on a proximal side of the rotarydrive nut 220. The proximal male hex coupling portion 228 of the rotarydrive head 224 is configured to mechanically engage with a female hexshaft coupling portion 232 of an end effector drive housing 234 at aproximal end of the end effector 204.

When the rotary drive shaft 212 is in a distal-most position, the femalehex coupling portion 226 of the rotary drive head 224 is mechanicallyengaged with the male hex coupling portion 230 of the rotary drive nut220. In this configuration, rotation of the rotary drive shaft 212actuates rotation of the rotary drive nut 220, which actuatestranslation of the threaded rotary drive member 222, which actuatestranslation of the I-beam 208 and cutting element 210. The orientationof the threading of the threaded rotary drive member 222 and the rotarydrive nut 220 may be established so that either clockwise orcounterclockwise rotation of the rotary drive shaft 212 will actuatedistal or proximal translation of the threaded rotary drive member 222,I-beam 208, and cutting element 210. In this manner, the direction,speed, and duration of rotation of the rotary drive shaft 212 can becontrolled in order to control the direction, speed, and magnitude ofthe longitudinal translation of the I-beam 208 and cutting element 210and, therefore, the closing and opening of the end effector 204 and thetransection stroke of the I-beam 208 along the first and second channels218 a, 218 b, as described above. In this illustrated embodiment,rotation of the rotary drive shaft 212 in a clockwise direction (asviewed from a proximal-to-distal vantage point) actuates clockwiserotation of the rotary drive nut 220, which actuates distal translationof the threaded rotary drive member 222, which actuates distaltranslation of the I-beam 208 and cutting element 210, which actuatesclosure of the end effector 204 and a distal transection stroke of theI-beam 208 and cutting element 210. Rotation of the rotary drive shaft212 in a counterclockwise direction provides the opposite effect, withthe I-beam 208 and cutting element 210 translating proximally.

FIGS. 10 and 11 show the rotary drive shaft 212 in a proximal-mostposition in which the male hex coupling portion 228 of the rotary drivehead 224 is mechanically engaged with the female hex shaft couplingportion 232 of the end effector drive housing 234. In thisconfiguration, rotation of the rotary drive shaft 212 actuates rotationof the end effector 204 relative to the shaft 202. Thus, the rotarydrive shaft 212 may be used to independently actuate the opening andclosing of the end effector 204, the proximal-distal transection strokeof the I-beam 208 and cutting element 210, and the rotation of endeffector 204.

FIGS. 12-15 illustrate another embodiment of an electrosurgical tool300. The tool 300 is generally configured and used similar to the tool100 of FIG. 1 and includes an elongate shaft 302, an end effector 304coupled to a distal end of the shaft 302 and including first and secondjaws 306 a, 306 b, and a proximal housing portion 330 (see FIGS. 16 and17) including a drive system and including a housing coupled to aproximal end of the shaft 302. Similar to the proximal housing portion106 of FIG. 1 discussed above, the proximal housing portion of the tool300 can be configured to operably couple to a tool driver of a roboticsurgical system, or the proximal housing portion can be configured to behandheld and operated manually. It will be appreciated by a personskilled in the art that the tool 300 can contain and/or can beconfigured to operatively connect to a generator for generating anelectrosurgical drive signal to drive the tool's drive system, which asdiscussed above can include multiple drive systems. In this illustratedembodiment, tissue-facing surfaces of each of the jaws 306 a, 306 b areconductive and are configured to apply energy to tissue engaged thereby.

The tool 300 includes cables 308, 310, 312, 314 that are configured tobe actuated to selectively cause opening of the end effector 304,closing of the end effector 304, and articulation of the end effector304 relative to the shaft 302. The cables 308, 310, 312, 314 areattached to the end effector 304, extend along solid surfaces of guidechannels in the end effector 304, a distal clevis 316, and a proximalclevis 318, and from there extend back through the shaft 302 to a theproximal housing portion.

The distal clevis 316 is configured to rotate 322 about a pin 324 thatdefines a pitch axis, e.g., the distal clevis is configured to rotateabout the pitch axis in response to cable actuation. For clockwiserotation about the pitch axis, a drive system in response to controlthereof, e.g., in response to motor force delivered thereto, pulls inidentical lengths of the third and fourth cables 312, 314 whilereleasing the same lengths of the first and second cables 308, 310. Thethird and fourth cables 312, 314 apply forces to the distal clevis 316at moment arms defined by guide channels of the third and fourth cables312, 314 through the distal clevis 316. Similarly, for counterclockwiserotation of the distal clevis 316 about the pitch axis, the drive systemin response to control thereof pulls in identical lengths of the firstand second cables 308, 310 while releasing the same lengths of the thirdand fourth cables 312, 314.

A pin 320 in distal clevis 316 is perpendicular to the pin 324 anddefines a pivot or yaw axis, about which the end effector 304 isconfigured to rotate 326 and about which the jaws 306 a, 306 b areconfigured to individually rotate 328 to open and close in response tocable actuation. The first and second cables 308, 310 attach to thefirst jaw 306 a, and the third and fourth cables 312, 314 attach to thesecond jaw 306 b. The attachment of the first and second cables 308, 310to jaw 242 is such that pulling in a length of one cable 308 or 310while releasing the same length of the other cable 308 or 310 causes thefirst jaw 306 a to rotate about the pin 320. Similarly, the attachmentof the third and fourth cables 312, 314 to the second jaw 306 b is suchthat pulling in a length of one cable 312 or 314 while releasing thesame length of the other cable 312 or 314 causes the second jaw 306 b torotate about the pin 320. A closure assembly of the tool 300 thusincludes the cables 308, 310, 312, 314.

Yaw rotations, i.e., rotations 326 in FIG. 15, correspond to bothrotating the jaws 306 a, 306 b in the same direction and through thesame angle. In particular, the drive system pulling in a length of thesecond cable 310 and releasing an equal length of the first cable 308will cause the first jaw 306 a to rotate in a clockwise direction aboutthe axis of pin 320. For this rotation, a guide channel in the first jaw306 a defines the moment arm at which the second cable 310 applies aforce to the first jaw 306 a, and the resulting torque causes the firstjaw 306 a to rotate clockwise and the first and second cables 308, 310to slide on the solid surface of guide channels in distal clevis 316. Ifat the same time the drive system pulls in a length of the fourth cable314 and releases the same length of the third cable 312, the second jaw306 b will rotate clockwise through an angle that is the same as theangle through which the first jaw 306 a rotates. Accordingly, the jaws306 a, 306 b maintain their positions relative to each other and rotateas a unit through a yaw angle. Counterclockwise rotation of the effector304 including the jaws 306 a, 306 b is similarly accomplished when thedrive system pulls in equal lengths of the first and third cables 308,312 while releasing the same lengths of the second and fourth cables310, 314.

Opening/closing of the end effector 304, i.e., rotations 328 in FIG. 15,are achieved by rotating the jaws 306 a, 306 b in opposite directions bythe same amount. To open the grip of the jaws 306 a, 306 b, the drivesystem pulls in equal lengths of the first and fourth cables 308, 314while releasing the same lengths of the second and third cables 310,312, causing the jaws 306 a, 306 b to rotate in opposite directions awayfrom each other. To close the grip of the jaws 306 a, 306 b, the drivesystem pulls in equal lengths of the second and third cables 310, 312while releasing the same lengths of the first and fourth cables 310,312, causing the jaws 306 a, 306 b to rotate in opposite directionstoward each other. When the tissue-facing surfaces of the jaws 306 a,306 b come into contact or are clamped on tissue, the tension in thesecond and third cables 252 and 253 can be kept greater than the tensionin the first and fourth cables 308, 314 in order to maintain grippingforces.

FIGS. 16 and 17 illustrate portions of the proximal housing portion 330of the tool 300. The proximal housing portion 330 includes a housing orchassis 332, three drive shafts 334, 336, 338, three toothed components340, 342, 344, and two levers 346, 348, and the proximal housing portion330 couples to the four cables 308, 310, 312, 314. The drive shafts 334,336, 338 are configured to operatively connect to motors of a controlsystem that drive the drive shafts 334, 336, 338.

The first drive shaft 334 acts as a pinion that engages a rack portionof the first toothed component 340. The first toothed component 340 isattached to the second cable 310 and moves in a straight line to pull inor release a length of second cable 310 as the drive shaft 334 turns.The first toothed component 340 also includes an arm containing anadjustment screw 350 that contacts the first lever 346. In particular,the adjustment screw 350 contacts the first lever 346 at an end oppositeto where the first cable 308 attaches to the first lever 346. A pivotpoint or fulcrum for the first lever 346 is on the third toothedcomponent 344 that acts as a rocker arm as described further below. Inoperation, as the first toothed component 340 moves, the adjustmentscrew 350 causes or permits rotation of the first lever 346 about thepivot point so that the lever 346 can pull in or release the first cable308. The connection of the first cable 308 to the first lever 346 andthe contact point of the adjustment screw 350 on the first lever 346 canbe made equidistant from the pivot point of the first lever 346, so thatwhen the first toothed component 346 pulls in (or releases) a length ofthe second cable 310, the first lever 346 releases (or pulls in) thesame length of the first cable 308. The first adjustment screw 350permits adjustment of the tension in the first and second cables 308,310 by controlling the orientation of the first lever 346 relative tothe position of the first toothed component 340.

The second drive shaft 336 similarly acts as a pinion that engages arack portion of the second toothed component 342. The second toothedcomponent 340 is attached to the third drive cable 310 and moves in astraight line to pull in or release a length of the third cable 310 asthe second drive shaft 336 turns. The first toothed component 340 alsoincludes an arm containing a second adjustment screw 352 that contactsthe second lever 348 at an end opposite to where the fourth cable 314attaches to the second lever 348. A pivot point or fulcrum for thesecond lever 348 is on the third toothed component 344, and the distanceof the connection of the fourth cable 314 from the pivot point of thesecond lever 348 can be made the same as the distance from the pivotpoint of the second lever 348 to the contact point of the secondadjustment screw 352 on the second lever 348. As a result, when thesecond toothed component 342 pulls in (or releases) a length of thethird cable 312, the second lever 348 releases (or pulls in) the samelength of the fourth cable 314. The second adjustment screw 352 permitsadjustment of the tension in the third and fourth cables 312, 314 bycontrolling the orientation of the second lever 348 relative to theposition of the second toothed component 342.

The first and second drive shafts 334, 336 can be operated to change theyaw angle or the grip of a wrist mechanism using the processes describedabove. For example, turning the first and second drive shafts 334, 336at the same speed in the same direction or in opposite directions willchange the grip or yaw.

The third drive shaft 338 engages an internal sector gear portion of thethird toothed component 344. The third toothed component 334 has a pivotattached to the chassis 332, so that as the third drive shaft 338 turns,the third toothed component 344 rotates about pivot pin 354. The thirdtoothed component 344 also includes protrusions (not visible in FIG. 16)that act as pivot points for the levers 346, 348. If the first andsecond toothed components 340, 342 are moved at the appropriate speedsand directions to maintain the orientations of the levers 346, 348,rotation of the third toothed component 344 will pull in (or release)equal lengths of the first and second cables 308, 310 and release (orpull in) the same lengths of the third and fourth cables 312, 314.

As shown in FIG. 16, the shaft 302 is attached in the proximal housingportion 330 to a helical gear 356, which is coupled to a drive shaft 358through an intervening helical gear 360. When a control system rotatesthe drive shaft 358, the helical gears 356, 360 rotate the shaft 302 andthereby change the roll angle of the end effector 304 at the distal endof the shaft 302.

The proximal housing portion 330 also includes a circuit board 362configured for electrical connection to a control system of a roboticsurgical system. The circuit board 362 can include memory or othercircuitry that sends an identification signal to the control system toindicate which instrument is connected to the control system and/or toprovide key parameters that the control system may need for properoperation of the instrument. Connection to electrical components of theend effector 304, e.g., to energize a cauterizing instrument or to relaysensor measurements, can be in the circuit board 362. However, aseparate electrical connection may be desired for energizing the endeffector 304, particularly when high voltages are required.

The proximal housing portion 330 also includes a cover 364 that enclosesmechanical and electrical components of the proximal housing portion330. Two levers 366 can be used to disengage the proximal housingportion 330 from the control system.

Pulleys and capstans can be used in in place of some toothed componentsof FIGS. 16 and 17. FIG. 18 illustrates another embodiment of a proximalhousing portion 368 that includes pulleys and capstans but is otherwisegenerally configured and used similar to the proximal housing portion330 of FIGS. 16 and 17. The proximal housing portion 368 includes ahousing or chassis 370, four drive shafts 372, 374, 376, 378, a pair ofcapstans 380, 382, a rocker arm 382 on which a first pair of pulleys 384and a second pair of pulleys 386 are mounted, helical gears 388, 390,and a circuit board 392. The four cables 308, 310, 312, 314 extendthrough the shaft 302 into the proximal housing portion 368.

The first and second cables 308, 310 pass from the shaft 302, windaround one or more first pulleys 384, and wrap around the first capstan380. The wrapping of the first and second cables 308, 310 around thecapstan 380 is such that when the first capstan 380 turns, a length ofone cable 308, 310 is pulled in and an equal length of the other thecable 308, 310 fed out. Similarly, the third and fourth cables 312, 314pass from the shaft 302, wind around one or more second pulleys 386, andare wrapped around the second capstan 382, so that when the secondcapstan 382 turns a length of one cable 312, 314 is pulled in and anequal length of the other cable 312, 314 is fed out. The second andthird drive shafts 374, 376 are respectively coupled to turn thecapstans 380, 382. A control system can thus turn the second and thirddrive shafts 374, 376 to change the yaw angle or the grip using theprocesses described above.

As mentioned above, the pulleys 384, 386 are mounted on the rocker arm382. The rocker arm 382 has a sector gear portion that engages thefourth drive shaft 378 and is coupled to the chassis 370 to rotate orrock about a pivot axis when the fourth drive shaft 378 turns. Thesector gear portion and pivot of the rocker arm 382 are designed so thatrotation of the rocker arm 382 primarily causes one set of pulleys 384or 386 to move toward its associated capstan 380 or 382 and the otherset of pulleys 384 or 386 to move away from its associated capstan 380or 382. This effectively pulls in lengths of one pair of cables 308, 310or 312, 314 and releases an equal length of the other pair of cables314, 312 or 308, 310. Rotation of the fourth drive shaft 378 can thuschange the pitch.

Using the first drive shaft 372 to turn the helical gears 388, 390 cancontrol roll angle as described above.

The circuit board 392 provides an interface to a control system asdescribed above. High voltage connections are generally made throughseparate electrical connections and wires that may be run through theproximal housing portion 368 and run through the shaft 302 to the endeffector 304. For example, in one embodiment of the invention, the tool300 is a bipolar cautery instrument and electrical wires or otherelectrical conductors (not shown) connect to a generator throughconnectors (not shown) on the proximal housing portion 368 and fromthere run with the cables 308, 310, 312, 314 through the shaft 302.Electrical energy for cautery can be delivered through contacts, whichengage the jaws 306 a, 306 b similar to brushes in a motor.

Embodiments of electrosurgical tools are further described in U.S. Pat.No. 9,119,657 entitled “Rotary Actuatable Closure Arrangement ForSurgical End Effector” filed Jun. 28, 2012 and U.S. Pat. No. 8,771,270entitled “Bipolar Cautery Instrument” filed Jul. 16, 2008, which arehereby incorporated by reference in their entireties.

As mentioned above, the electrosurgical tools discussed herein can bemanually operated or electrically operated. More and more surgicalprocedures are being performed using electrically-powered surgicaldevices that are either hand-held or that are coupled to a surgicalrobotic system.

In general, one or more motors can be used to drive variouselectrosurgical device functions. The device functions can vary based onthe particular type of electrosurgical device, but in general anelectrosurgical device can include one or more drive systems that can beconfigured to cause a particular action or motion to occur, such asshaft and/or end effector rotation, end effector articulation, jawopening and/or closing, energy delivery, etc. Each drive system caninclude various components, as discussed above, such as one or moregears that receive a rotational force from the motor(s) and thattransfer the rotational force to one or more drive shafts to causerotary or linear motion of the drive shaft(s). The motor(s) can belocated within the electrosurgical device itself or, in the alternative,coupled to the electrosurgical device such as via a robotic surgicalsystem. Each motor can include a rotary motor shaft that is configuredto couple to the one or more drive systems of the electrosurgical deviceso that the motor can actuate the drive system(s) to cause a variety ofmovements and actions of the electrosurgical device.

It should be noted that any number of motors can be used for driving anyone or more drive systems on a surgical device. For example, one motorcan be used to actuate two different drive systems for causing differentmotions. Moreover, in certain embodiments, the drive system can includea shift assembly for shifting the drive system between different modesfor causing different actions. A single motor can in other aspects becoupled to a single drive assembly. An electrosurgical device caninclude any number of drive systems and any number of motors foractuating the various drive systems. The motor(s) can be powered usingvarious techniques, such as by a battery on the electrosurgical deviceor by a power source connected directly to the electrosurgical device orconnected through a robotic surgical system.

Additional components, such as one or more sensors or one or more meterdevices, can be coupled to the motor(s) in order to determine and/ormonitor at least one of displacement of a drive system coupled to themotor or a force on the motor during actuation of the drive system. Forexample, an electrosurgical tool can include one or more sensors or oneor more meter devices and can include a control unit (e.g., a circuitboard or computer system including a processor) configured to transmitsensed/metered data to a control system that controls the motor.Embodiments of surgical device control units configured to transmitsensed/metered data are further described in previously mentioned U.S.Pat. No. 8,771,270 entitled “Bipolar Cautery Instrument” filed Jul. 16,2008. Embodiments of position sensors (e.g., a Hall Effect sensor) todetermine cutting element position along an end effector, embodiments offiring sensors (e.g., a rheostat or variable resistor) to determine whena firing trigger or other firing actuator has been actuated to start amotor to drive firing, embodiments of closure sensors (e.g., a digitalsensor or an analog sensor) to determine when a closure trigger or otherclosure actuator has been actuated to start a motor to drive closure,embodiments of load sensors (e.g., a pressure sensor) to determineclosure pressure force exerted by an end effector, embodiments of forcesensors to determine user-applied force to the device's actuator toadjust an amount of power provided by a motor based on an amount of theuser-applied force, embodiments of sensors (e.g., a position switch, aHall Effect sensor, or an optical sensor) to determine an angle of theend effector's closure, and embodiments of impedance sensors to measureimpedance of clamped tissue are variously described in U.S. PatentPublication No. 2012/0292367 entitled “Robotically-Controlled EndEffector” filed Feb. 13, 2012, U.S. Patent Publication No. 2015/0209059entitled “Methods And Devices For Controlling Motorized SurgicalDevices” filed Jan. 28, 2014, U.S. Pat. No. 5,558,671 entitled“Impedance Feedback Monitor For Electrosurgical Instrument” filed Sep.24, 1996, and U.S. Patent Publication No. 2015/0209573 entitled“Surgical Devices Having Controlled Tissue Cutting And Sealing,” whichare hereby incorporated by reference in their entireties.

In certain embodiments, when the at least one motor is activated, itscorresponding rotary motor shaft drives the rotation of at least onecorresponding gear assembly located within a drive system of anelectrosurgical tool. The corresponding gear assembly can be coupled toat least one corresponding drive shaft, thereby causing linear and/orrotational movement of the at least corresponding drive shaft. Whilemovement of two or more drive shafts can overlap during different stagesof operation of the drive system, each motor can be activatedindependently from each other such that movement of each correspondingdrive shaft does not necessarily occur at the same time or during thesame stage of operation.

When the at least one drive shaft is being driven by its correspondingmotor, a rotary encoder, used, can determine the rotational position ofthe motor, thereby indicating linear or rotational displacement of theat least one drive shaft. The rotary encoder can be coupled to the motorto monitor the rotational position of the motor, thereby monitoring arotational or linear movement of a respective drive system coupled tothe motor. Additionally or in the alternative, when the correspondingmotor is activated, a torque sensor, if used, can determine the force onthe motor during linear or rotary movement of the at least one actuationshaft. The torque sensor can be coupled to the motor to determine ormonitor an amount of force being applied to the motor during deviceoperation. It is also contemplated that other ways to determine ormonitor force on the motor can include (i) measuring current though themotor by using a sensor or a meter device; or (ii) measuring differencesbetween actual velocity of the motor or components, which may include acombination of a distance travelled and an expired time, and thecommanded velocity.

Various embodiments of motors of control systems and various embodimentsof tool drivers that house such motors therein are further described inInternational Patent Publication No. WO 2014/151952 entitled “CompactRobotic Wrist” filed Mar. 13, 2014, International Patent Publication No.WO 2014/151621 entitled “Hyperdexterous Surgical System” filed Mar. 13,2014, patent application Ser. No. 15/200,283 entitled “Methods, Systems,And Devices For Initializing A Surgical Tool” filed Jul. 1, 2016, and inU.S. patent application Ser. No. 15/237,653 entitled “Methods, Systems,And Devices For Controlling A Motor Of A Robotic Surgical System” filedAug. 16, 2016, which are hereby incorporated by reference in theirentireties.

As mentioned above, one or more motors as well as the control systemassociated therewith can be disposed within an electrosurgical tool,e.g., with a housing of a proximal housing portion thereof, or can belocated outside of the electrosurgical tool, such as part of a surgicalrobotic system that operatively couples to the electrosurgical tool. Aswill be appreciated by a person skilled in the art, electroniccommunication between various components of a robotic surgical systemcan be wired or wireless. A person skilled in the art will alsoappreciate that all electronic communication in the robotic surgicalsystem can be wired, all electronic communication in the roboticsurgical system can be wireless, or some portions of the roboticsurgical system can be in wired communication and other portions of thesystem can be in wireless communication.

FIG. 19 illustrates one embodiment of a robotic surgical system 400 thatincludes a patient-side portion 402 that is positioned adjacent to apatient 404, and a user-side portion 406 that is located a distance fromthe patient, either in the same room and/or in a remote location. Thepatient-side portion 402 generally includes one or more robotic arms 408and one or more tool assemblies 410 that are configured to releasablycouple to a robotic arm 408. The user-side portion 406 generallyincludes a vision system 412 for viewing the patient 404 and/or surgicalsite, and a control system 414 for controlling the movement of therobotic arms 408 and each tool assembly 410 during a surgical procedure.

The control system 414 can have a variety of configurations and can belocated adjacent to the patient (e.g., in the operating room), remotefrom the patient (e.g., in a separate control room), or distributed attwo or more locations (e.g., the operating room and/or separate controlroom(s)). As an example of a distributed system, a dedicated systemcontrol console can be located in the operating room, and a separateconsole can be located in a remote location. The control system 414 caninclude various components, such as components that enable a user toview a surgical site of the patient 404 being operated on by thepatient-side portion 402 and/or to control one or more parts of thepatient-side portion 402 (e.g., to perform a surgical procedure at thesurgical site). In at least some embodiments, the control system 414 canalso include one or more manually-operated input devices, such as ajoystick, exoskeletal glove, a powered and gravity-compensatedmanipulator, or the like. The one or more input devices can controlmotors which, in turn, control the movement of the surgical system,including the robotic arms 408 and tool assemblies 410.

The patient-side portion 402 can have a variety of configurations. Asillustrated in FIG. 19, the patient-side portion 402 can couple to anoperating table 416. However, in other embodiments, the patient-sideportion 402 can be mounted to a wall, to the ceiling, to the floor, orto other operating room equipment. Further, while the patient-sideportion 402 is shown as including two robotic arms 408, more or fewerrobotic arms 408 may be included. Furthermore, the patient-side portion402 can include separate robotic arms 408 mounted in various positions,such as relative to the surgical table 416 (as shown in FIG. 19).Alternatively, the patient-side portion 402 can include a singleassembly that includes one or more robotic arms 408 extending therefrom.

One or more motors (not shown) are disposed within a motor housing 418that is coupled to an end of the arm 408. A tool or drive system housing420 on a surgical tool can house a drive system (not shown) and can bemounted to the motor housing 418 to thereby operably couple the motor(s)to the drive system, e.g., the housing 110 of the tool 100 can bemounted to the motor housing 418, the housing 332 of the tool 300 can bemounted to the motor housing 41, etc. As a result, when the motors areactivated by the control system, the motor(s) can actuate the drivesystem. As shown in FIG. 19, an end effector 422 including a pair ofjaws extends from each tool housing 420. During surgery, the endeffector 422 can be placed within and extend through a trocar 424 thatis mounted on the bottom of a carrier 426 extending between the motorhousing 418 and a trocar support. The carrier 426 allows the tool to betranslated into and out of the trocar 424.

Generally, as discussed above, a control system can control movement andactuation of a surgical device such as an electrosurgical tool. Forexample, the control system can include at least one computer system andcan be operably coupled to the at least one motor that drives a drivesystem on the surgical device. The computer system can includecomponents, such as a processor, that are configured for running one ormore logic functions, such as with respect to a program stored in amemory coupled to the processor. For example, the processor can becoupled to one or more wireless or wired user input devices (“UIDs”),and the processor can be configured for receiving sensed information,aggregating the sensed information, and computing outputs based at leastin part on the sensed information. These outputs can be transmitted tothe drive system of surgical device to control the surgical deviceduring use.

In certain embodiments, the control system can be a closed-loop feedbacksystem. The stored data within the computer system can includepredetermined threshold(s) for one or more stages of operation of thedrive system. When the control system is actuated, it drives one or moremotors on or coupled to the surgical device, consequently actuating thedrive system through each stage of operation. During each stage ofoperation, the control system can receive feedback input from one ormore sensors coupled to the motor(s). The computer system can aggregatethe received feedback input(s), perform any necessary calculations,compare it to the predetermined threshold for the corresponding stage ofoperation, and provide output data to the motor(s). If at any timeduring each stage of operation the control system determines that thereceived input exceeds a maximum predetermined threshold or is less thana minimum predetermined threshold, the control system can modify theoutput data sent to the motor based on the programmed logic functions.For example, the control system can modify the output data sent to themotor(s) to reduce a current delivered to the motor to reduce motorforce or a voltage delivered to the motor to thereby reduce a rotationalspeed of the motor(s) or to stop movement of the motor(s).

In certain embodiments of methods, systems, and devices provided herein,a control system can be configured to control power of a motor thatdrives translation of a cutting element of an electrosurgical tool tocontrol a speed of the cutting element. Such motor control may allow thecutting element to translate at a speed to efficiently cut tissue ofdifferent thicknesses, e.g., translate faster while cutting thinnertissue than while cutting thicker tissue, such motor control may helpprevent cutting element and/or end effector breakage to by preventingthe cutting element from moving too quickly, such motor control maycompensate for cutting element translation when the end effector is atdifferent articulation angles since the more the end effector isarticulated the shorter the translation in embodiments in which thecutting element is formed of laminate bands that flex when articulated,and/or such motor control may allow the cutting element to translateslower at a start of a translation stroke than subsequently in thestroke to account for the cutting element possibly not encounteringtissue to cut until the cutting element has already translated adistance from its start position due to the tissue's positioning withinthe electrosurgical tool's end effector. The power of the motor can becontrolled based on an impedance of the tissue engaged by the endeffector, and/or based on a longitudinal position of the cutting elementalong the end effector. In an exemplary embodiment, the power of themotor is based on at least two factors, which may provide a moreaccurate indication of the tissue's thickness and whether the cuttingelement is translating through tissue (as opposed to, e.g., translatingalong empty space between tissue-facing surfaces of an end effector'sclosed jaws). For example, the power of the motor can be controlledbased on an impedance of tissue engaged by the end effector and based ona current of the motor, which is a parameter indicative of impedance.For another example, the power of the motor can be controlled based oncurrent of the motor and based on a distance of the cutting element fromits start position before beginning translation along the end effector.

In at least some embodiments, the power of the motor can be controlledto be constrained between upper and lower predetermined motor currentthresholds, which correspond to upper and lower predetermined cuttingelement speeds. The cutting element can thus be guaranteed to translatebetween a certain predetermined minimum speed and a certainpredetermined maximum speed, which may help ensure that the cuttingelement continually moves to cut tissue and/or may help ensure that themotor does not overexert (e.g., run at a power above a safe level).

FIG. 20 illustrates one embodiment of operation of a control system tocontrol power of a motor that drives translation of a cutting element ofan electrosurgical tool to control a speed of the cutting element. Thecontrol system is operatively coupled to the electrosurgical tool thatincludes the cutting element, such as by the electrosurgical tool beingremovably and replaceably coupled to a tool driver that is operativelycoupled to the control system. Section A of FIG. 20 illustrates currentI of the motor over time, section B of FIG. 20 illustrates speed ν ofthe cutting element over time, section C of FIG. 20 illustratesimpedance Z of tissue over time, and section D of FIG. 20 illustratespower P (or torque τ) of the motor over time. The current I of the motorcorresponds to a load or force experienced by the motor, whichcorresponds to a force of compression exerted by the electrosurgicaltool, e.g., force applied to tissue grasped between jaws of theelectrosurgical tool.

As shown in section A of FIG. 20, the control system is configured toconstrain the current I of the motor between an upper current threshold500 and a lower current threshold 502. The upper and lower currentthresholds 500, 502 are each predetermined, e.g., are preprogrammed aslimits into the control system. The upper and lower current thresholds500, 502 are each variable when no power P is being applied, e.g.,between time t₀ and time t₁, and are each substantially constant whenpower P is being applied, e.g., after time t₁. A person skilled in theart will appreciate that a value may not be precisely constant butnevertheless considered to be substantially constant due to any numberof factors, such as manufacturing tolerances and sensitivity ofmeasurement devices. The upper and lower current thresholds 500, 502being variable when no power P is being applied reflects closure of theelectrosurgical tool's end effector on tissue, e.g., load increasing astissue is clamped while the end effector moves from an open position toa closed position. The upper and lower current thresholds 500, 502 beingsubstantially constant when power P is being applied reflects that theend effector is closed.

In general, the control system is configured to control the current I ofthe motor and the speed ν of the cutting element but is not able tocontrol the impedance Z of the tissue or the power P of the motor. Thecontrol system is configured to receive data indicative of the impedanceZ of the tissue, e.g., via an impedance sensor or a voltage and currentsensor from which impedance can be measured, and data indicative of thepower of the motor, e.g., via a torque sensor coupled to the motor todetermine or monitor an amount of force being applied to the motorduring device operation. The control system can control the current I,and hence control the speed ν, based on one or both of the impedance Zand the power P.

The speed ν rises from zero to a first speed ν₂ shortly after time t₀.Section B of FIG. 20 shows in solid line a baseline speed 504 in whichthe speed ν is substantially constant at the first speed ν2 until thecutting element stops moving at time t₅, e.g., until the speed ν dropsto zero shortly before time t₅. Section A of FIG. 20 shows in solid linea baseline current 508 that corresponds to the baseline speed 504. Thebaseline current 508 is not bounded between the upper and lower currentthresholds 500, 502. The baseline speed 504 and baseline current 508 areshown for reference. Section A of FIG. 20 shows in dotted line acontrolled current 510 that is controlled by the control system based onthe impedance Z and the power P and that is bounded between the upperand lower current thresholds 500, 502. Section B of FIG. 20 shows indotted line a varying speed 506 in which the speed ν varies over timedue to the current I control. Section D of FIG. 20 shows in solid line abaseline power 512 for reference and in dotted line a power 514 thatresults from the control system's control of the current I and speed ν.

During a first stage of operation between time t₀ and time t₁, no powerP is being applied, the current I increases, and the impedance Zdecreases. Also in the first stage of operation the speed ν rises fromzero to the first speed ν2 shortly after time t₀, as mentioned above,and then remains substantially constant at the first speed ν2. At timet₁, the end effector has been closed, and power P begins being applied.During a second stage of operation between time t₁ and time t₂, thecurrent I continues to increase but remains below the upper currentthreshold 500, the speed ν is substantially constant at the first speedν₂, and the impedance Z continues to decrease but remains above apredetermined lower threshold Z₁ of impedance.

At time t₂, the impedance Z falls to the lower threshold Z₁ ofimpedance. The impedance Z being at the lower threshold Z₁ of impedanceis indicative of the current I being at the upper threshold 500. Inresponse to the impedance Z being at the lower threshold Z₁ ofimpedance, the control system causes the current I to decrease, as shownby the controlled current 510 starting to decrease at time t₂ anddecreasing throughout a third stage of operation between time t₂ andtime t₃. The speed ν thus decreases from the first speed ν₂ to a second,lower speed ν₁ and is substantially constant at the lower speed ν₁during the third stage of operation. Without the control system'scontrol, the current I would increase above the upper current threshold500, as shown by the baseline current 508 between time t₂ and time t₃,and the speed ν would remain substantially constant at the speed ν₂, asshown by the baseline speed 504 between time t₂ and time t₃. During thethird stage of operation the power P increases, as shown by the dottedline power 514 between time t₂ and time t₃.

At time t₃, the power P reaches a predetermined upper threshold P₁. Thepower P being at the upper threshold P₁ of power is indicative of thecurrent I being at the lower threshold 502. In response to the power Pbeing at the upper threshold P₁, the control system causes the current Ito increase, as shown by the controlled current 510 starting to increaseat time t₃ and remaining above the lower threshold 502 throughout afourth stage of operation between time t₃ and time t₄. The speed ν thusincreases from the lower speed ν₁ to the higher speed ν₂ and issubstantially constant at the higher speed ν₂ during the fourth stage ofoperation. Without the control system's control, the current I wouldfall below the lower current threshold 502, as shown by the baselinecurrent 508 between time t₃ and time t₄, and the speed ν would remainsubstantially constant at the speed ν₂, as shown by the baseline speed504 between time t₃ and time t₄. During the fourth stage of operationthe impedance Z increases.

At time t₄, the impedance Z reaches a predetermined upper threshold Z₂of impedance while power P is being applied. In response to theimpedance Z being at the upper threshold Z₂ of impedance while power Pis being applied, the control system causes the current I to increase,as shown by the controlled current 510 starting to increase at time t₄and remaining above the lower threshold 502 throughout a fifth stage ofoperation between time t₄ and time t₅. The speed ν thus increases fromits current speed ν₂ to a higher speed ν₃ and is substantially constantat the higher speed ν₃ during the fifth stage of operation. Without thecontrol system's control, the current I would fall below the lowercurrent threshold 502, as shown by the baseline current 508 between timet₄ and time t₅, and the speed ν would remain substantially constant atthe speed ν₂, as shown by the baseline speed 504 between time t₄ andtime t₅. During the fourth stage of operation the impedance Z increases.At time t₅, the speed ν decreases to zero in response to the motorceasing to drive the cutting element, e.g., in response to the motorceasing to run.

In certain embodiments, a control system can be configured to controlspeed of an electrosurgical tool's cutting element, e.g., by controllingmotor output, based on an angle at which an end effector of theelectrosurgical tool is articulated relative to an elongate shaft of theelectrosurgical tool. The control system can be configured to controlthe speed of the cutting element based on articulation angle alone or inaddition to one or more additional factors, e.g., tissue impedance,longitudinal position of the cutting element along the end effector,etc.

One embodiment of a control system configured to control speed of anelectrosurgical tool's cutting element based on an angle at which an endeffector of the electrosurgical tool is articulated relative to anelongate shaft of the electrosurgical tool is described with respect toan electrosurgical tool 600 illustrated in FIG. 21. Although the controlis discussed with respect to the tool 600 of FIG. 21, control can besimilarly achieved with other electrosurgical tools.

The tool 600 is generally configured and used similar to otherelectrosurgical tools described herein, e.g., the tool 100 of FIG. 1,the tool 200 of FIG. 8, and the tool 300 of FIG. 12. The tool 600includes a proximal clevis 602, a distal clevis 604 pivotally attachedto the proximal clevis 602, and an end effector 606 pivotally attachedto the distal clevis 604. The tool 600 includes a plurality of cables(not shown) configured to facilitate end effector opening, end effectorclosing, and end effector articulation, as discussed herein. FIG. 21shows a cable path 608 for one of the cables around the pivotalconnection between the distal clevis 604 and the end effector 606. Thecable path 608 is a circular arc. A length of the cable along the cablepath 608 is provided by the following equation, where α is pitch angleof the end effector 606, β is yaw angle of the end effector 606, and Δis the distance or displacement of the cutting element from its startposition before beginning to translate:

${{Cable}\mspace{14mu}{Length}} = {{{2\; L} + \Delta} = {\frac{L\;\alpha}{\tan\left( \frac{\alpha}{2} \right)} + \frac{L\;\beta}{\tan\left( \frac{\beta}{2} \right)}}}$

When the pitch angle α does not equal zero and the yaw angle β does notequal zero, the motor rotation angle θ (in radians) is provided by thefollowing equation, where C is the motor pinion radius:

$\theta = {\left\lbrack {\frac{L\;\alpha}{\tan\left( \frac{\alpha}{2} \right)} + \frac{L\;\beta}{\tan\left( \frac{\beta}{2} \right)} - {4\; L}} \right\rbrack\frac{1}{C}}$

The pitch angle α and the yaw angle β are known by the control system,as the control system caused the articulation at those angles. Thelength L of the cable is also known by the control system, as it is aknown value of the cable. Thus, the distance Δ traveled by the cuttingelement can be determined by the control system. The control system cantherefore calculate the distance Δ traveled by the cutting element andcontrol the motor based on the distance Δ. For example, in response tothe distance Δ reaching a predetermined minimum distance, the controlsystem can be configured to increase the speed of the cutting element'stranslation, e.g., by controlling the motor's output. The control systemcan be configured to repeatedly and sequentially calculate the distanceΔ during the cutting element's translation to identify when the distanceΔ reaches the predetermined minimum distance. Similarly, a position ofthe motor, e.g., the motor rotation angle θ, can be determined by thecontrol system using the known values of α,β, L, and C.

An electrosurgical tool can include a stop mechanism configured as abackstop for the tool's cutting element. The cutting element can beconfigured to abut the stop mechanism when in its start position, whichmay help ensure that the cutting element is in its start position beforebeginning to translate. For example, the cutting element may distallytranslate from its start position to cut tissue and then be proximallyretracted back before being distally translated again to cut additionaltissue. The cutting element should be retracted back to its startposition to help ensure that the cutting element's distal translation isaccurately controlled during its next distal translation stroke.Retracting the cutting element proximally until the cutting elementabuts the stop mechanism may help ensure that the cutting element is inits start position before being distally translated. For anotherexample, the cutting element can be controlled by a control system toabut the stop mechanism during articulation of the tool's end effector,to help ensure that if the cutting element is actuated with the endeffector articulated, the cutting element will begin its translationalong the end effector from its start position and thus be moreaccurately controlled by the control system.

FIG. 22 illustrates one embodiment of an electrosurgical tool 700 thatincludes a stop mechanism 702 for a cutting element 708 of the tool 700.In this illustrated embodiment the stop mechanism is a distal-facingsurface of a lower jaw 704 of the tool's end effector that is configuredto abut a proximal-facing surface of the cutting element 708 when thecutting element 708 is in its start position, as shown in FIG. 22. Thetool 700 is generally configured and used similar to otherelectrosurgical tools described herein, e.g., the tool 100 of FIG. 1,the tool 200 of FIG. 8, and the tool 300 of FIG. 12. A control systemoperatively coupled to the tool 700 can be configured to cause proximalretraction of the cutting element 708 along the end effector, asdiscussed herein, until no further proximal movement is possible,thereby indicating that the cutting element 708 has abutted the stopmechanism 702.

FIG. 23 illustrates another embodiment of an electrosurgical tool 710that includes a stop mechanism 712 for a cutting element 714 of the tool710. In this illustrated embodiment the stop mechanism is a rod or barextending laterally at a proximal end of the tool's end effector 716.The stop mechanism 712, e.g., a distal surface thereof, is configured toabut a proximal-facing surface of the cutting element 714 when thecutting element 714 is in its start position, as shown in FIG. 23. Thetool 710 is generally configured and used similar to otherelectrosurgical tools described herein, e.g., the tool 100 of FIG. 1,the tool 200 of FIG. 8, and the tool 300 of FIG. 12. A control systemoperatively coupled to the tool 710 can be configured to cause proximalretraction of the cutting element 714 along the end effector 716, asdiscussed herein, until no further proximal movement is possible,thereby indicating that the cutting element 718 has abutted the stopmechanism 712.

The stop mechanism 702 of FIG. 22 is positioned such that the cuttingelement 708 in its start position is immediately proximal totissue-facing surfaces of the end effector's jaws (only the lower jaw704 is shown, for clarity of illustration of the stop mechanism 702).The cutting element 708 is thus configured to immediately begin cuttingtissue grasped by the end effector when the cutting element 708 beginsdistally translating along the end effector. The stop mechanism 712 ofFIG. 23 is positioned a distance 706 proximally beyond a location wherethe cutting element 714 begins cutting tissue grasped by the endeffector 716 when the cutting element 714 begins distally translatingalong the end effector 716. The distance 706 may help prevent thecutting element 714 from moving into a position where it mayaccidentally cut tissue during articulation of the end effector 716and/or may help prevent stroke changes from moving the cutting element714 a position where it may accidentally cut tissue. In contrast, suchdistance is substantially zero in the embodiment of FIG. 22. A personskilled in the art will appreciate that a parameter may not be preciselyat a value, e.g., the distance may not be precisely zero, butnevertheless considered to be substantially at that value due to anynumber of factors, such as manufacturing tolerances and sensitivity ofmeasurement devices.

FIG. 24 illustrates one embodiment of a process 800 of controlling speedof an electrosurgical tool's cutting element based on an angle at whichan end effector of the electrosurgical tool is articulated relative toan elongate shaft of the electrosurgical and based on the cuttingelement's distance from its start position. The process 800 is describedwith respect to the tool 600 of FIG. 21 can be similarly implementedwith other electrosurgical tools. In the process 800, the end effector606 is closed 802, such as by the control system receiving a user inputand in response to the user input causing the end effector 606 to movefrom its open position to its closed position. The tool 600 applies 804additional clamp force to the end effector 606 and tissue for sealing ofthe tissue. The control system receives 806 a user input to fire thecutting element. In response to the user input to fire, the controlsystem interrogates 808 a position of the motor that is used fortranslation of the cutting element, e.g., the motor that is operativelycoupled with the drive system for cutting element translation. Theinterrogation 808 can be, for example, calculation of the motor rotationangle θ using the equation above. In response to the user input to fire,the control system also determines 810 a distance of the cutting elementfrom its start position. For example, the determination 810 can becalculating the distance Δ traveled by the cutting element using theequation above. If the position of the cutting element is determined 812to be acceptably close to the cutting element's start position, and is agenerator operatively coupled to the tool 600 is determined 814 to notbe activated (e.g., energy is not currently being applied), then thecutting element is fired 816. Determining 812 whether the cuttingelement is acceptably close to the cutting element's start position caninclude determining whether the calculated distance Δ is substantiallyequal to zero or whether the calculated distance Δ is within apredetermined acceptable tolerance value from zero. If the position ofthe cutting element is determined 812 to be acceptably close to thecutting element's start position, and is a generator operatively coupledto the tool 600 is determined 814 to be activated (e.g., energy iscurrently being applied), then the cutting element is not fired 818 andan error notification is provided 820, such as by the control systemproviding an error message on a display screen, sounding an alarm, etc.If the position of the cutting element is determined 812 to not beacceptably close to the cutting element's start position, then thecutting element is not fired 818 and an error notification is provided820.

In certain embodiments of methods, systems, and devices provided herein,a control system can be configured to control an electrosurgical toolsuch that an end effector of the tool compresses tissue engaged by theend effector with different compression forces based on whether or notthe electrosurgical tool is applying energy. In an exemplary embodiment,the compressive force is higher during energy application than whenenergy is not being applied. In other words, when the end effector isgrasping tissue, the control system can be configured to cause the endeffector to clamp the tissue with a lower force when energy is not beingapplied than when energy is being applied. Varying the compressive forcebased on whether energy is being applied or not can allow the endeffector to compress tissue more during energy application, which maymore effectively seal the tissue than if the tissue was being compressedless during the energy application. For example, heat from RF energy maybe more efficiently transferred to tissue clamped at a highercompressive force. For another example, ultrasonic energy may be moreefficiently transmitted to tissue clamped at a higher compressive force.

Alternatively or in addition to the control system being configured tocontrol an electrosurgical tool such that an end effector of the toolcompresses tissue engaged by the end effector with different compressionforces based on whether or not the electrosurgical tool is applyingenergy, the control system can be configured to compensate forover-closing of the end effector by automatically adjusting a gapbetween jaws of the end effector to be at a minimum predetermined gap.In other words, the control system can be configured to causetissue-facing surfaces of the jaws to be a predetermined distance fromone another. Adjusting the gap between the jaws may help preventelectrode(s) on the tissue-facing surface of one jaw from contactingelectrode(s) on the tissue-facing surface of the other jaw, therebyavoiding a short when energy is being applied using the electrodes onthe tissue-facing surface. Adjusting the gap between the jaws allows theelectrosurgical tool to not have conductive or non-conductive gapsetting features such as protrusions or bumps on facing surfaces of theend effector's jaws, which may simply manufacturing and/or reduce devicecost.

Alternatively or in addition to the control system being configured tocontrol an electrosurgical tool such that an end effector of the toolcompresses tissue engaged by the end effector with different compressionforces based on whether or not the electrosurgical tool is applyingenergy, and alternatively or in addition to the control system beingconfigured to compensate for over-closing of the end effector byautomatically adjusting a gap between jaws of the end effector to be ata minimum predetermined gap, the control system can be configured tocontrol a velocity of end effector closure based on compressive forcethat the end effector is applying to tissue between the jaws of the endeffector and based on a location of the cutting element relative to theend effector. Such control of closure velocity may help preventover-compression of tissue and/or help prevent electrodes on facingsurfaces of the jaws from contacting one another and creating a short.

FIG. 25 illustrates one embodiment of operation of a control systemconfigured to control an electrosurgical tool such that an end effectorof the tool compresses tissue engaged by the end effector with differentcompression forces based on whether or not the electrosurgical tool isapplying energy. The control system is operatively coupled to theelectrosurgical tool, such as by the electrosurgical tool beingremovably and replaceably coupled to a tool driver that is operativelycoupled to the control system. Section A of FIG. 25 illustrates endeffector compressive or clamp force F over time, section B of FIG. 25illustrates a gap δ between facing surfaces of end effector jaws overtime, and section C of FIG. 25 illustrates impedance Z of tissue andmotor power over time.

As shown in section A of FIG. 25, during a tissue manipulation stage ofoperation in which the control system is controlling closure of the endeffector, e.g., is causing movement of the jaws from an open position toa closed position, the closure system is configured to prevent fromclamp force F from exceeding a first predetermined maximum threshold.The first predetermined maximum threshold is 2.0 lbs. in thisillustrated embodiment but can have other values based on, e.g., endeffector size, maximum motor power, etc. Section B of FIG. 25illustrates the closure of the end effector in the tissue manipulationstage of operation, with the gap δ decreasing over time as the endeffector moves closes. Section C of FIG. 25 shows in the tissuemanipulation stage of operation as the end effector closes that theimpedance Z of the tissue clamped by the end effector is decreasing andthat no power is being applied, e.g., no is being delivered to thetissue.

A clamping stage of operation follows the tissue manipulation stage ofoperation. As shown in section A of FIG. 25, in response to an energytrigger at time t₁, e.g., in response to the control system receiving aninput that energy is to be applied to tissue, the control system causesthe clamping force F to increase to a second predetermined maximumthreshold. The first predetermined maximum threshold is 6.5 lbs. in thisillustrated embodiment but can have other values based on, e.g., endeffector size, maximum motor power, etc. Section B of FIG. 25 shows thatthe gap δ decreases in the clamping stage as the end effector is forcedfurther closed. Section C of FIG. 25 shows that in the clamping stagethe impedance Z of the tissue clamped by the end effector is decreasingand that no power is being applied. Thus, following the energy triggerat time t₁, period of time, e.g., from time t₁ to time t₂, passes beforeenergy begins to be applied at time t₂.

A sealing stage of operation follows the clamping stage of operation. Inresponse to the clamping force F achieving the second predeterminedmaximum threshold, the control system causes energy to be applied, e.g.,power to begin being delivered. As shown in section A of FIG. 25, theclamping force F is substantially constant during the energyapplication. As shown in section B of FIG. 25, the gap δ decreasesduring the energy application, despite the clamping force F beingsubstantially constant, because the energy applied to the tissue changesthe properties of the tissue. As shown in section C of FIG. 25, theimpedance Z has an inverse relationship with the power. At time t₃energy stops being applied.

FIG. 26 shows a table of electrosurgical tool functions and whether ornot they are possible to be performed in the various stages of operationas illustrated in FIG. 25. In other words, the control system isconfigured to either prevent or allow certain functions from occurringduring different stages of the electrosurgical tool's operation. Cuttingelement translation is not possible during the tissue manipulation,clamping, and sealing stages or when the energy is triggered, butcutting element translation is possible during a cutting stage ofoperation. The cutting stage of operation can follow the sealing stageof operation, as in the illustrated embodiment of FIG. 25. End effectorarticulation and elongate shaft rotation are each possible during thetissue manipulation stage of operation but are not permitted during theclamping, sealing, and cutting stages of operation or when the energy istriggered. Grasping of tissue (e.g., end effector opening/closing) ispossible during the tissue manipulation stage of operation and whenenergy is triggered but is not permitted during the clamping, sealing,and cutting stages of operation. Sealing (energy delivery) is possibleduring the clamping, sealing, and cutting stages of operation and whenthe energy is triggered but is not permitted during the tissuemanipulation stage of operation.

FIG. 27 illustrates one embodiment of operation of a control systemconfigured to control an electrosurgical tool to compensate forover-closing of the tool's end effector by automatically adjusting a gapbetween jaws of the end effector to be at a minimum predetermined gap.The control system is operatively coupled to the electrosurgical tool,such as by the electrosurgical tool being removably and replaceablycoupled to a tool driver that is operatively coupled to the controlsystem. Section A of FIG. 27 illustrates impedance Z of tissue overtime, section B of FIG. 27 illustrates a gap δ between facing surfacesof end effector jaws over time, and section C of FIG. 27 illustratesmotor power over time. The initial tissue gap δ at time t₀ is 0.006″ andthe initial tissue impedance Z is 50Ω in this illustrated embodiment buteach can be other values.

As shown in FIG. 27, when a short (short circuit) occurs, the impedanceZ drops to substantially zero, the gap δ drops to a predeterminedminimum gap δ₁, and the power drops to substantially zero. The controlsystem can this be configured to determine when a short occurs bydetermining whether the impedance Z is substantially zero, the gap δequals the predetermined minimum gap δ₁, and the power is substantiallyzero. In response to determining that a short has occurred, the controlsystem is configured to cause the end effector to open such that the gapδ increases to a minimum closed loop gap δ₂ that is greater than thepredetermined minimum gap δ₁. FIG. 27 illustrates a short occurring attime t₁ and the gap δ immediately thereafter being increased to be theminimum closed loop gap δ₂. The impedance Z and power thus normalizeback to their pre-short levels, and energy application continuesnormally until time t₂.

In at least some embodiments, the control system can be configured tocause a short to occur. The short will trigger the control system to setthe gap δ at the minimum closed loop gap δ₂. Thus, causing a short canreset the gap δ to be at a known value, which may allow the controlsystem to wait to trigger the application of energy until the gap δ isreset in order to ensure that a short will not happen upon the start ofenergy delivery or soon thereafter because the jaws were too closetogether when energy was triggered.

FIG. 28 illustrates one embodiment of operation of a control systemconfigured to control a velocity of end effector closure based oncompressive force that the electrosurgical tool's end effector isapplying to tissue between jaws of the end effector and based on alocation of a cutting element relative to the end effector. The controlsystem is operatively coupled to the electrosurgical tool, such as bythe electrosurgical tool being removably and replaceably coupled to atool driver that is operatively coupled to the control system. Section Aof FIG. 28 illustrates velocity ν between facing surfaces of endeffector jaws over time (e.g., end effector closure speed over time),section B of FIG. 28 illustrates end effector compressive or clamp forceF over time, and section C of FIG. 28 illustrates jaw closure angle θover time. The solid lines in each of sections A, B, and C correspondsto baseline tissue, and the dotted lines in each of sections A, B, and Ccorresponds to stiffer tissue with a same geometry as the baselinetissue.

As shown in section A of FIG. 28, in response to an input to close theend effector at time t₀, the control system causes the end effector tobegin closing at a first predetermined velocity ν₁. The end effectorcloses at the first predetermined velocity ν₁ until the end effector'stissue-facing surfaces contact tissue at time t₁. Section B of FIG. 28reflects the tissue contact at time t₁ by the clamping force F beingsubstantially zero until time t₁. Section C of FIG. 28 shows that thejaw angle θ decreases as the jaws move closer together between time t₀and time t₁.

In response to the clamping force F increasing, the control system canbe configured to cause the velocity ν to decrease from the firstvelocity ν₁ to a second predetermined velocity ν₂ that is less than thefirst predetermined velocity ν₁. In other words, the force F increasingfrom substantially zero indicates that the end effector has begun toclamp tissue such that the closure can slow down to, e.g., help avoidmotor overexertion and/or help avoid overly traumatizing the tissue.Section C of FIG. 28 shows that the jaw angle θ decreases as the jawsmove closer together between time t₁ and time t₂. Section C of FIG. 28shows that the jaw angle θ decreases as the jaws move closer togetherbetween time t₁ and time t₂.

In response to the force F increasing to a predetermined threshold forceF₂, which occurs at time t₂, the control system is configured to causethe velocity ν to drop from the second predetermined velocity ν₂. Thevelocity ν can thus continue to decrease as the compressive force Fincreases between time t₂ and time t₃, at which time closure is completefor baseline tissue, or time t₄, at which time closure is complete forstiffer tissue. Section C of FIG. 28 shows that the jaw angle θdecreases as the jaws move closer together between time t₂ and time t₃or t₄.

In certain embodiments of methods, systems, and devices provided herein,a control system can be configured to detect if a short (short circuit)has occurred between electrodes of an electrosurgical too. The controlsystem can also be configured to allow energy to be delivered to theelectrodes is no short is detected and configured to prevent energy frombeing delivered to the electrodes if a short is detected. The controlsystem may thus improve safety by preventing the electrodes from beingenergized when there is no tissue contacting the electrodes, such as ifthe electrosurgical tool's end effector has closed but isunintentionally not grasping tissue, if previously grasped tissue wasnot grasped securely and has slipped out of the end effector, or ifenergy was unintentionally triggered for delivery when the end effectorhas not grasped any tissue. Conventional generators are unable throughthe monitoring of various parameters to tell the difference between anend effector of an electrosurgical tool engaging thin tissue, in whichcase energy can be safely delivered, and the electrosurgical toolexperiencing a short, in which case energy should not be delivered inorder to prevent damage to the tool and/or non-tissue matter engaged bythe end effector. The control system being configured to determinewhether or not a short has occurred may allow energy to be delivered tothin tissue from the generator when otherwise the generator would notallow energy to be delivered to the thin tissue due to the generator'sinability to recognize that tissue is in fact engaged.

The control system can be configured to detect a short in a variety ofways. In an exemplary embodiment, the control system is configured tomonitor an electrical parameter during end effector closure, e.g., asjaws of the end effector move from an open position to a closedposition. In response to the electrical parameter dropping to apredetermined minimum parameter threshold, the control system can beconfigured to cause the end effector to open. The control system is alsoconfigured to monitor a gap between jaws of the end effector and onlycause the end effector's jaws to open when the electrical parameter hasdropped to the predetermined minimum parameter threshold (e.g., is equalto or below the predetermined minimum parameter threshold) and the gaphas dropped to a predetermined minimum distance threshold (e.g., isequal to or below the predetermined minimum distance threshold). Thecontrol system may thus not prematurely cause opening of the endeffector in response to the electrical parameter dropping to thepredetermined minimum parameter threshold prior to the jaws beingclosed. The control system is configured to continue monitoring theelectrical parameter during the end effector's opening and, based on theelectrical parameter's value during the opening, determine if a shortoccurred or if tissue was clamped between the jaws in the closedposition. In an exemplary embodiment, the electrical parameter isimpedance, but other electrical parameters can be used, such asresistance, current, and power. Thinner tissue has lower impedance thanthicker tissue such that a low impedance can incorrectly indicate to agenerator that tissue is not engaged by an electrosurgical tool when infact thin tissue is engaged by the tool. Monitored impedance stayingsubstantially constant during the end effector opening is indicative ofa short, and monitored impedance spiking upward, and remaining spiked,is also indicative of a short. Monitored impedance gradually increasingduring the end effector opening is indicative of the end effectorengaging tissue and that a short has not occurred.

FIG. 29 illustrates one embodiment of operation of a control systemconfigured to monitor an electrical parameter during end effectorclosure to facilitate detection of a short. The control system isoperatively coupled to the electrosurgical tool that includes the endeffector, such as by the electrosurgical tool being removably andreplaceably coupled to a tool driver that is operatively coupled to thecontrol system. Section A of FIG. 29 illustrates impedance Z (in Ohms)of tissue over time, Section B of FIG. 29 illustrates a gap δ betweenfacing surfaces of jaws of an end effector over time, and Section C ofFIG. 29 illustrates generator power P over time. FIG. 29 illustrates anembodiment in which the electrical parameter monitoring by the controlsystem to facilitate short detection is impedance, but as mentionedabove, other electrical parameters may be used.

End effector closure begins at a time prior to time t₀ in FIG. 29. Thecontrol system is configured to start monitoring impedance, such as bygathering impedance data via one or more impedance sensors, in responseto the start of end effector closure, e.g., in response to the controlsystem receiving an input requesting end effector closure. The controlsystem is also configured to start monitoring a gap between the endeffector's jaws, such as by gathering position data via one or moreposition sensors, in response to the start of end effector closure,e.g., in response to the control system receiving an input requestingend effector closure. In response to the impedance being at or below apredetermined minimum impedance threshold for a predetermined amount oftime and the gap being at or below a predetermined minimum distancethreshold for the predetermined amount of time, the control system isconfigured to cause the end effector to open. The control system doesnot receive an outside input, e.g., an input instruction from a user, toopen the end effector. Instead, the control system is configured toautomatically cause the end effector opening as part of a shortdetection scheme. The predetermined minimum impedance threshold in thisillustrated embodiment is about 1.1Ω, and the predetermined minimumdistance threshold in this illustrated embodiment is about 0.0065″,although other predetermined minimum impedance thresholds andpredetermined minimum distance thresholds can be used. The predeterminedamount of time in this illustrated embodiment is defined by the timebetween time t₀ and time t₁.

As shown in Section A of FIG. 29, the control system causes the endeffector to open at time t₁, as indicated by the gap δ beginning toincrease at time t₁. Sections A and B of FIG. 29 illustrate threescenarios that can result when the end effector opens. A first scenariois the impedance spiking during the end effector opening, as indicatedby a first impedance line 900, which indicates a short condition. Inresponse to the control system detecting that the impedance spikes abovea predetermined impedance threshold prior to the gap δ reaching apredetermined gap threshold and/or detecting that the impedance spikesbefore a predetermined amount of time has elapsed after end effectoropening (e.g., the predetermined amount of time being the time betweentime t₁ and time t₂), the control system causes the end effector tofully open since a short has been detected. The predetermined impedancethreshold is about 2.0Ω in this illustrated embodiment but can be othervalues. The predetermined gap threshold is about 0.020″ in thisillustrated embodiment but can be other values. The end effector openingin the first scenario is indicated by a first gap line 902.

A second scenario is the impedance remaining substantially constantduring the end effector opening, as indicated by a second impedance line904, which indicates a short condition. In response to the controlsystem detecting that the impedance remains substantially constant untilthe gap δ increases to a predetermined gap threshold and/or detectingthat the impedance remains substantially constant for a predeterminedamount of time after end effector opening begins (e.g., thepredetermined amount of time being the time between time t₁ and timet₃), the control system causes the end effector to fully open since ashort has been detected. The predetermined gap threshold is about 0.020″in this illustrated embodiment but can be other values. The end effectoropening in the second scenario is indicated by a second gap line 906.

In response to detecting the short under either the first scenario orthe second scenario, the control system prevents energy from beingapplied. The control system can also be configured to provide anotification of the detected short, such as by providing an audiblesound, providing a message on a display, etc., so a user can, forexample, take corrective action, such as repositioning theelectrosurgical tool to attempt again to grasp tissue.

A third scenario is the impedance gradually increasing during the endeffector opening, as indicated by a third impedance line 908, whichindicates that the end effector is grasping tissue. In response to thecontrol system detecting that the impedance is gradually increasinguntil the gap δ increases to a predetermined gap threshold and/ordetecting that the impedance gradually increases for a predeterminedamount of time after end effector opening begins (e.g., thepredetermined amount of time being the time between time t₁ and time t₃,which is the same predetermined amount of time used in the secondscenario), the control system causes the end effector to begin closingagain since a short has not been detected. The predetermined gapthreshold is about 0.020″ in this illustrated embodiment, same as thepredetermined gap threshold used in the second scenario, but can beother values. The end effector closing in the third scenario isindicated by a third gap line 910. When the end effector has returned tothe closed position, at time t₄ in FIG. 29, the control system isconfigured to cause energy to be delivered to the tissue via theelectrosurgical tool. The energy delivery is indicated by the power Pbeginning at time t₄.

In certain embodiments of methods, systems, and devices provided herein,a control system can be configured to control an end effector'scompression force on tissue based on a type of energy being delivered tothe tissue via the end effector. In other words, the control system canbe configured to vary end effector pressure based on energy modality. Inan exemplary embodiment, the control system can be configured to adjustthe compression force based on whether only RF energy is being deliveredto the tissue, only ultrasonic energy is being delivered to the tissue,or both RF energy and ultrasonic energy is being delivered to thetissue. Varying the pressure applied to tissue by the end effectorduring energy delivery may facilitate efficient coagulation of tissue,which is accomplished with RF energy, and efficient cutting of tissue,which is accomplished with ultrasonic energy. When both RF energy andultrasonic energy are being simultaneously applied to tissue, theultrasonic energy is being used to reinforce coagulation of tissue beingcauses by the RF energy. However, ultrasonic energy tends to causetissue cutting. By reducing an amount of end effector pressure when bothRF energy and ultrasonic energy are being applied to tissue, coagulationcan occur without the tissue being cut, thereby allowing for tissuesealing prior to the tissue being cut, e.g., before ultrasonic energy isapplied without RF energy simultaneously being applied, which mayfacilitate tissue healing and/or reduce bleeding.

In an exemplary embodiment, the control system is configured to monitoran overall intensity of energy being delivered to the tissue duringapplication of energy to the tissue to determine an amount ofcompression force that should be applied to the tissue. Impedance of thetissue is indicative of overall intensity of energy being delivered tothe tissue. Thus, the control system is configured to monitor impedanceof the tissue grasped by the end effector during the application ofenergy to the tissue, such as by gathering impedance data via one ormore impedance sensors. Based on the monitored impedance and based onthe type of energy being applied, the control system is configured tovary the end effector compression force.

FIG. 30 illustrates one embodiment of operation of a control systemconfigured to control an end effector's compression force on tissuebased on a type of energy being delivered to the tissue via the endeffector. The control system is operatively coupled to theelectrosurgical tool that includes the end effector, such as by theelectrosurgical tool being removably and replaceably coupled to a tooldriver that is operatively coupled to the control system. Section A ofFIG. 30 illustrates impedance Z (in Ohms) of tissue over time, andSection B of FIG. 30 illustrates end effector compression force (tipload) F_(tip load) (in pounds) over time.

During a first stage of operation between time t₀ and time t₂, tissuecoagulation occurs due to energy application to the tissue. As shown inFIG. 30, energy application to tissue begins at time t₀. The energyapplication begins with only RF energy being delivered, as reflected byan RF line 1000 in Section A of FIG. 30, which is shown as a dottedline. While only the RF energy is being delivered, in this illustratedembodiment, the tissue impedance is about 25Ω and the end effectorcompression force is about 5.5 pounds. RF energy is the only type ofenergy being applied to the tissue until time t₁, when ultrasonic energybegins being applied simultaneously with RF energy. The control systemis configured to begin the ultrasonic energy automatically as part ofachieving tissue coagulation. An ultrasonic line 1002 in Section A ofFIG. 30, which is shown as a solid line, reflects the impedance of thetissue causes by the ultrasonic energy. Overall impedance is shown by anoverall impedance line 1004. In some instances, overall impedance may beless than expected after time t₃, as shown by impedance line 1006, butthe control system operates the same way. The tissue impedance drops attime t₁ due to two types of energy being applied to the tissue. In thisillustrated embodiment, the tissue impedance drops from about 25Ω (timet₀ to time t₁) to about 17Ω (time t₁ to time t₂), which is the sum ofthe impedance (about 12Ω) due to RF energy and the impedance (about 5Ω)due to ultrasonic energy. In response to detecting the impedance dropand two modes of energy being applied, the control system causes the endeffector compression force to decrease, in this illustrated embodimentfrom about 5.5 pounds to about 4.5 pounds.

At time t₂, the impedance decreases while two modes of energy are beingapplied to the tissue. As shown by the RF and ultrasonic lines 1000,1002, the overall impedance decreases at time t₂ to about 10Ω. Enough RFenergy cannot be delivered if impedance is under about 10Ω. This overallimpedance is less than the overall impedance when only RF energy isbeing applied (between time t₀ and time t₁). The increase in ultrasonicenergy and decrease in RF energy in this second stage of operation(between time t₂ to time t₃) is configured to be caused automatically bythe control system as part of enhancing the tissue coagulation achievedin the first stage of operation. In response to the impedance decreasingand two modes of energy being applied to the tissue, the control systemcauses the end effector compression force to decrease, in thisillustrated embodiment from about 4.5 pounds to about 3.5 pounds.

At time t₃, the balance of RF energy and ultrasonic energy returns tothe same levels as between times t₁ and t₂. Thus, in this third stage ofoperation (between time t₃ and time t₅), coagulation occurs. As shown bythe RF and ultrasonic lines 1000, 1002, the overall impedance begins toincrease at time t₃. In response to detecting the impedance increase andtwo modes of energy being applied, the control system causes the endeffector compression force to increase, in this illustrated embodimentfrom about 3.5 pounds to about 4.5 pounds. At time t₄, the overallimpedance increases again in response to ultrasonic energy being stoppedand only RF energy being applied, similar to the RF energy applicationbetween time t₀ and time t₁. In response to detecting the impedanceincrease and only one mode of energy being applied, the control systemcauses the end effector compression force to increase, in thisillustrated embodiment from about 4.5 pounds to about 5.5 pounds.

At time t₅ a fourth stage of operation (time t₅ to time t₇) begins inwhich ultrasonic energy but not RF energy is applied such that thetissue is cut. Although overall impedance decrease at time t₅ inresponse to only ultrasonic energy being applied, the control systemmaintains the end effector compression force since only ultrasonicenergy is being applied instead of only RF energy or both RF energy andultrasonic energy.

In certain embodiments of methods, systems, and devices provided herein,a control system can be configured to monitor one or more parameters ofan electrosurgical tool operatively coupled thereto, e.g., via a tooldriver. The control system can be configured to monitor the parameter(s)while operatively coupled to a generator, also referred to herein as anESU (electrosurgical unit). The control system can be configured tomanipulate the monitored parameter data and to transmit the manipulatedparameter data to the generator. The generator can thus make decisionsbased on the manipulated parameter data rather than on the unmanipulateddata. In this way, the generator can be spoofed or fooled by the controlsystem into making decisions that would not result if the generator madedecisions based on the unmanipulated parameter data, e.g., because itwould result in the generator operating outside of its predeterminednormal operating conditions. In other words, the control system can beconfigured to force the generator to operate outside its predeterminednormal operating conditions by feeding it manipulated data that isdifferent than the unmanipulated data. For example, the control systemcan transmit manipulated tissue impedance data to the generator to causethe generator to deliver energy that it would not deliver based on theunmanipulated impedance data because it would violate the generator'spredetermined normal operating conditions. Some generators, particularlyolder generators, lack the processing capability to consider certainparameters in determining energy to deliver and/or have predeterminednormal operating conditions that outdate operating capabilities of moremodern electrosurgical tools and control systems. Allowing the controlsystem to override generators by providing manipulated data to thegenerators may allow these older generators to be used with more modernelectrosurgical tools and control systems since the control system knowsthe capabilities of the generator, e.g., by being preprogrammed with thegenerator's operating capabilities.

FIG. 31 illustrates one embodiment of a control system 1100 configuredto monitor one or more parameters of an electrosurgical tool 1102operatively coupled thereto and to manipulate the parameter data beforetransmitting the manipulated data to a generator 1104. In thisillustrated embodiment, the control system 1100 is configured to monitorvoltage/current and load applied by the electrosurgical tool's endeffector. The control system is 1100 is configured to manipulate thevoltage/current data and the load data by processing the voltage/currentdata and the load data through transformers 1106, 1108 in parallel. Thetransformed voltage/current data and the transformed load data can thenbe used by the generator 1104 to make decisions, e.g., how much energyto deliver to the electrosurgical tool 1102 for application to tissue bythe tool's end effector.

FIG. 32 illustrates another embodiment of a control system 1110configured to monitor one or more parameters of an electrosurgical tool1112 operatively coupled thereto and to manipulate the parameter databefore transmitting the manipulated data to a generator 1114. Theelectrosurgical tool 1112 in this illustrated embodiment is a wet fieldcoagulation device, but other electrosurgical tools can be used. In thisillustrated embodiment, the control system 1110 is configured to monitorimpedance of tissue engaged by the electrosurgical tool 1112, manipulatethe impedance data, and transmit the manipulated impedance data to thegenerator 1114, which is configured to use the manipulated impedancedata in determining energy to deliver to the tool 1112 via the controlsystem 1110. The control system 1110 is configured to manipulate theimpedance data using first and second switches S_(A) and S_(B) and firstand second resistors R₁ and R₂.

FIG. 33 shows a table illustrating four modes of impedance dataprocessing by the control system 1110. Based on the measured impedance,the control system 1110 is configured to determine that the generatorshould run at a higher power level than the generator is configured torun under normal operating conditions, e.g., should provide more powerthan the generator is configured to provide under normal operatingconditions. Depending on how high a power level the control system 1110determines is needed based on the measured impedance, the control system1110 can close selected one or more of the switches S_(A), S_(B), andS_(C). The control system 1110 can be pre-programmed with impedancelevels corresponding to different power levels. In a first mode thefirst and second switches S_(A) and S_(B) are open, and the impedancedata bypasses the first and second resistors R₁ and R₂ and istransmitted to the generator 1114 without modification. The generator1114 is thus making decisions based on “real” data that has not beenmanipulated by the control system 1110 to fool or spoof the generator1114. In a second mode the first switch S_(A) is closed and the secondswitch S_(B) is open, and the impedance data is manipulated by passingthrough the first resistor R_(A) before being received by the generator1114. The generator 114 is thus being spoofed or fooled by the controlsystem 1110 in the second mode. In a third mode the first switch S_(A)is open and the second switch S_(B) is closed, and the impedance data ismanipulated by passing through the second resistor R_(B) before beingreceived by the generator 1114. The generator 114 is thus being spoofedor fooled by the control system 1110 in the third mode. In a fourth modethe first and second switches S_(A) and S_(B) are closed, and theimpedance data is manipulated by passing through the first and secondresistors R₁ and R₂ before being received by the generator 1114. Thegenerator 114 is thus being spoofed or fooled by the control system 1110in the fourth mode.

FIG. 34 illustrates another embodiment of a control system 1116configured to monitor one or more parameters of an electrosurgical tool1118 operatively coupled thereto and to manipulate the parameter databefore transmitting the manipulated data to a generator 1120. Theelectrosurgical tool 1118 in this illustrated embodiment is a wet fieldcoagulation device, but other electrosurgical tools can be used. In thisillustrated embodiment, the control system 1116 is configured to monitorparameter(s) from the electrosurgical tool 1118, manipulate the data,and transmit the manipulated data to the generator 1120, which isconfigured to use the manipulated data in determining energy to deliverto the tool 1118 via the control system 1116. The control system 1116 isconfigured to manipulate the parameter data using first, second, andthird switches A, B, C and a transformer. In general, the control system1116 is configured to force the generator 1120 to deliver energy as iftissue engaged by the tool 1118 is thick when the tissue is in realitythin, as indicated by the sensed parameter(s).

FIG. 35 illustrates operability of the control system 1116 when variousones of the first, second, and third switches A, B, C are closed andwhen the monitored parameter is impedance. Maximum power P from thegenerator 1120 is shown as 130 W in this illustrated embodiment, butother maximum powers are possible. In a first mode the first switch A isclosed and the second and third switches B, C are open, as representedby curve A in FIG. 35. For a sensed impedance between Z₂ and Z₃, thecontrol system 1116 is configured to operate in the first mode toachieve maximum power. The first mode corresponds to medium thicknesstissue being engaged by the tool 1118. In a second mode the secondswitch B is closed and the first and third switches A, C are open, asrepresented by curve B in FIG. 35. For a sensed impedance between Z₃ andZ₄, the control system 1116 is configured to operate in the second modeto achieve maximum power. The second mode corresponds to thick tissuebeing engaged by the tool 1118. In a third mode the third switch C isclosed and the first and second switches A, B are open, as representedby curve C in FIG. 35. For a sensed impedance between Z₁ and Z₂, thecontrol system 1116 is configured to operate in the third mode toachieve maximum power. The third mode corresponds to thin tissue beingengaged by the tool 1118. In this illustrated embodiment the manipulatedimpedance in the second mode has a 1:2 ratio with the sensed impedance,which is the impedance in the first mode. In this illustrated embodimentthe manipulated impedance in the third mode has a 1:5 ratio with thesensed impedance.

As discussed above, the control systems disclosed herein can beimplemented using one or more computer systems, which may also bereferred to herein as digital data processing systems and programmablesystems.

One or more aspects or features of the control systems described hereincan be realized in digital electronic circuitry, integrated circuitry,specially designed application specific integrated circuits (ASICs),field programmable gate arrays (FPGAs) computer hardware, firmware,software, and/or combinations thereof. These various aspects or featurescan include implementation in one or more computer programs that areexecutable and/or interpretable on a programmable system including atleast one programmable processor, which can be special or generalpurpose, coupled to receive data and instructions from, and to transmitdata and instructions to, a storage system, at least one input device,and at least one output device. The programmable system or computersystem may include clients and servers. A client and server aregenerally remote from each other and typically interact through acommunication network. The relationship of client and server arises byvirtue of computer programs running on the respective computers andhaving a client-server relationship to each other.

FIG. 36 illustrates one exemplary embodiment of a computer system 1200.As shown, the computer system 1200 includes one or more processors 1202which can control the operation of the computer system 1200.“Processors” are also referred to herein as “controllers.” Theprocessor(s) 1202 can include any type of microprocessor or centralprocessing unit (CPU), including programmable general-purpose orspecial-purpose microprocessors and/or any one of a variety ofproprietary or commercially available single or multi-processor systems.The computer system 1200 can also include one or more memories 1204,which can provide temporary storage for code to be executed by theprocessor(s) 1202 or for data acquired from one or more users, storagedevices, and/or databases. The memory 1204 can include read-only memory(ROM), flash memory, one or more varieties of random access memory (RAM)(e.g., static RAM (SRAM), dynamic RAM (DRAM), or synchronous DRAM(SDRAM)), and/or a combination of memory technologies.

The various elements of the computer system 1200 can be coupled to a bussystem 1212. The illustrated bus system 1212 is an abstraction thatrepresents any one or more separate physical busses, communicationlines/interfaces, and/or multi-drop or point-to-point connections,connected by appropriate bridges, adapters, and/or controllers. Thecomputer system 1200 can also include one or more network interface(s)1206 that enable the computer system 1200 to communicate with remotedevices, e.g., motor(s) coupled to the drive system that is locatedwithin the surgical device or a robotic surgical system, one or moreinput/output (IO) interface(s) 1208 that can include one or moreinterface components to connect the computer system 1200 with otherelectronic equipment, such as sensors located on the motor(s), and oneor more storage device(s) 1210. The storage device(s) 1210 can includeany conventional medium for storing data in a non-volatile and/ornon-transient manner. The storage device(s) 1210 can thus hold dataand/or instructions in a persistent state, i.e., the value(s) areretained despite interruption of power to the computer system 1200.

A computer system can also include any of a variety of other softwareand/or hardware components, including by way of non-limiting example,operating systems and database management systems. Although an exemplarycomputer system is depicted and described herein, it will be appreciatedthat this is for sake of generality and convenience. In otherembodiments, the computer system may differ in architecture andoperation from that shown and described here.

A person skilled in the art will appreciate that the present inventionhas application in conventional minimally-invasive and open surgicalinstrumentation as well application in robotic-assisted surgery.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

One skilled in the art will appreciate further features and advantagesof the invention based on the above-described embodiments. Accordingly,the invention is not to be limited by what has been particularly shownand described, except as indicated by the appended claims. Allpublications and references cited herein are expressly incorporatedherein by reference in their entirety.

What is claimed is:
 1. A surgical system, comprising: a surgical toolincluding an elongate shaft, first and second jaws at a distal end ofthe elongate shaft, a housing at a proximal end of the elongate shaft, aclosure assembly disposed at least partially in the housing andconfigured to be actuated to move the jaws between an open position anda closed position, and at least two electrodes configured to applyenergy to tissue clamped between the jaws; a control system; and a tooldriver operatively coupled to the control system and configured to beremovably and replaceably operatively connected to the housing of thesurgical tool; wherein the control system is configured to: actuate theclosure assembly to move the jaws between the open position and theclosed position, when the jaws are in the closed position, determinewhether an electrical parameter associated with the surgical tool is ator below a predetermined threshold value, in response to the electricalparameter associated with the surgical tool being determined to be at orbelow the predetermined threshold value, actuate the closure assembly tocause the jaws to move from the closed position toward the openposition, determine if during the movement of the jaws from the closedposition toward the open position the electrical parameter changed orremained substantially constant, receive an instruction to deliverenergy to the at least two electrodes, and in response to the receivedinstruction, allow energy to be delivered to the at least two electrodesif it was determined that the electrical parameter remainedsubstantially constant during the movement of the jaws from the closedposition toward the open position, and prevent energy from beingdelivered to the at least two electrodes if it was determined that theelectrical parameter changed during the movement of the jaws from theclosed position toward the open position; and wherein the electricalparameter includes current of a motor of the tool driver, and the motoris configured to drive the closure assembly to move jaws to the closedposition.
 2. The surgical system of claim 1, wherein the control systemis configured to cause the motor to drive the closure assembly.
 3. Thesurgical system of claim 1, wherein the control system is a component ofa robotic surgical system, and the control system is configured toactuate the closure assembly in response to a user input to the roboticsurgical system.
 4. The surgical system of claim 1, further comprising asensor operatively coupled to the control system and configured to sensethe current.
 5. The surgical system of claim 1, wherein the motor isconfigured to drive the closure assembly such that a gap between facingsurfaces of the first and second jaws increases.
 6. The surgical systemof claim 5, wherein the motor is configured to drive the closureassembly such that the gap between the facing surfaces of the first andsecond jaws increases to a predetermined maximum gap.
 7. The surgicalsystem of claim 5, wherein the motor is configured to, after theincreasing of the gap, drive the closure assembly such that the gapbetween the facing surfaces of the first and second jaws decreases. 8.The surgical system of claim 7, wherein the motor is configured to drivethe closure assembly such that the gap between the facing surfaces ofthe first and second jaws decreases prior to either allowing the energyto be delivered to the at least two electrodes or preventing the energyfrom being delivered to the at least two electrodes.
 9. The surgicalsystem of claim 1, wherein the control system and the tool driver arecomponents of a robotic surgical system.
 10. The surgical system ofclaim 1, wherein the control system includes a processor.